JP2019147945A - Production method and production device for fiber-reinforced thermoplastic resin - Google Patents
Production method and production device for fiber-reinforced thermoplastic resin Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
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- 238000000034 method Methods 0.000 claims abstract description 32
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- JBKVHLHDHHXQEQ-UHFFFAOYSA-N epsilon-caprolactam Chemical group O=C1CCCCCN1 JBKVHLHDHHXQEQ-UHFFFAOYSA-N 0.000 claims description 28
- 238000005520 cutting process Methods 0.000 claims description 15
- 230000000704 physical effect Effects 0.000 abstract description 17
- 239000000463 material Substances 0.000 description 125
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 53
- 239000000047 product Substances 0.000 description 31
- 238000000465 moulding Methods 0.000 description 23
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 17
- 239000002994 raw material Substances 0.000 description 9
- 238000002156 mixing Methods 0.000 description 7
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- 238000004898 kneading Methods 0.000 description 5
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- 238000002844 melting Methods 0.000 description 4
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- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
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- 229920000178 Acrylic resin Polymers 0.000 description 1
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- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229920000571 Nylon 11 Polymers 0.000 description 1
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- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
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- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
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- 229920002223 polystyrene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
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Abstract
Description
本開示は、繊維強化熱可塑性樹脂の製造技術に関し、とくに、繊維強化熱可塑性樹脂の製造方法及び製造装置に関する。 The present disclosure relates to a technique for manufacturing a fiber reinforced thermoplastic resin, and more particularly, to a method and an apparatus for manufacturing a fiber reinforced thermoplastic resin.
炭素繊維やガラス繊維などにより強度を向上させた繊維強化プラスチックが開発されている。繊維強化プラスチックは、軽量で強度が高い上に、安価で耐久性にも優れていることから、様々な分野での応用が期待されている。 Fiber reinforced plastics with improved strength using carbon fiber or glass fiber have been developed. Fiber reinforced plastics are lightweight and high in strength, are inexpensive and have excellent durability, and are expected to be applied in various fields.
そのような分野の一つとして、自動車などの移動体の製造がある。自動車などの移動体の構造部品を繊維強化プラスチックで製造することにより、必要な強度を維持しつつ車体を軽量化することができるので、二酸化炭素排出量の削減など、環境問題の解決にも大きく貢献することができる。 One such field is the manufacture of moving objects such as automobiles. By manufacturing structural parts of moving bodies such as automobiles with fiber reinforced plastics, the body can be reduced in weight while maintaining the required strength, greatly reducing environmental issues such as reducing carbon dioxide emissions. Can contribute.
移動体などの分野に繊維強化プラスチックを応用するためには、繊維強化プラスチックを成形した成形物を短時間で大量に製造するための製造技術が不可欠である。本発明者らは、製品の仕様に応じた良好な物理的特性を有する繊維強化プラスチックを短時間で製造する技術の開発が急務であると認識し、本開示の技術に想到した。 In order to apply fiber reinforced plastics to fields such as moving bodies, manufacturing technology for manufacturing a large number of molded articles obtained by molding fiber reinforced plastics in a short time is indispensable. The present inventors have recognized that there is an urgent need to develop a technique for producing a fiber reinforced plastic having good physical characteristics according to product specifications in a short time, and have come up with the technique of the present disclosure.
本開示は、このような課題に鑑みてなされ、その目的は、良好な物理的特性を有する繊維強化熱可塑性樹脂を短時間で製造するための技術を提供することである。 The present disclosure has been made in view of such problems, and an object thereof is to provide a technique for manufacturing a fiber-reinforced thermoplastic resin having good physical characteristics in a short time.
上記課題を解決するために、本開示のある態様の繊維強化熱可塑性樹脂の製造方法は、複数の長繊維をチャンバー内に導入するステップと、チャンバー内で長繊維に熱可塑性樹脂のモノマーの液体又は溶液を含浸させるステップと、モノマーが含浸された長繊維を加熱することによりモノマーを重合させるステップと、熱可塑性樹脂が含浸された長繊維をチャンバーから引き出すステップと、を備える。 In order to solve the above problems, a method for producing a fiber-reinforced thermoplastic resin according to an aspect of the present disclosure includes a step of introducing a plurality of long fibers into a chamber, and a liquid of a monomer of a thermoplastic resin into the long fibers in the chamber. Alternatively, the method includes a step of impregnating the solution, a step of polymerizing the monomer by heating the long fiber impregnated with the monomer, and a step of extracting the long fiber impregnated with the thermoplastic resin from the chamber.
本開示の別の態様の繊維強化熱可塑性樹脂の製造装置は、複数の長繊維に熱可塑性樹脂のモノマーの液体又は溶液を含浸させるための含浸チャンバーと、モノマーが含浸された長繊維を加熱することによりモノマーを重合させるための重合チャンバーと、熱可塑性樹脂が含浸された長繊維を重合チャンバーから引き出すための移動部と、を備える。 An apparatus for producing a fiber-reinforced thermoplastic resin according to another aspect of the present disclosure heats a long fiber impregnated with a monomer, and an impregnation chamber for impregnating a plurality of long fibers with a liquid or solution of a monomer of a thermoplastic resin. Thus, a polymerization chamber for polymerizing the monomer and a moving part for pulling out the long fiber impregnated with the thermoplastic resin from the polymerization chamber are provided.
本開示によれば、良好な物理的特性を有する繊維強化熱可塑性樹脂を短時間で製造するための技術を提供することができる。 According to the present disclosure, it is possible to provide a technique for producing a fiber-reinforced thermoplastic resin having good physical characteristics in a short time.
本開示の実施の形態に係る繊維強化熱可塑性樹脂の成形物の製造方法は、熱可塑性樹脂及び繊維を溶融混練して押し出すことにより製造された第１の繊維強化熱可塑性樹脂素材と、熱可塑性樹脂を繊維に含浸させることにより製造された第２の繊維強化熱可塑性樹脂素材とを混合するステップと、混合された第１及び第２の繊維強化熱可塑性樹脂素材を加熱するステップと、加熱された第１及び第２の繊維強化熱可塑性樹脂素材を成形するステップとを備える。ここで、第２の繊維強化熱可塑性樹脂素材に含まれる繊維の長さの平均値は、第１の繊維強化熱可塑性樹脂素材に含まれる繊維の長さの平均値よりも長い。 A method for manufacturing a molded product of a fiber reinforced thermoplastic resin according to an embodiment of the present disclosure includes: a first fiber reinforced thermoplastic resin material manufactured by melt kneading and extruding a thermoplastic resin and fibers; Mixing the second fiber reinforced thermoplastic resin material produced by impregnating the fiber with the resin, heating the mixed first and second fiber reinforced thermoplastic resin materials, and heating Forming first and second fiber reinforced thermoplastic resin materials. Here, the average value of the length of the fiber contained in the 2nd fiber reinforced thermoplastic resin material is longer than the average value of the length of the fiber contained in the 1st fiber reinforced thermoplastic resin material.
高い流動性を有する第１の繊維強化熱可塑性樹脂素材に、弾性率や強度などの物理的特性を付与することが可能な第２の繊維強化熱可塑性樹脂素材を適当量混合することにより、プレス成形による高速な成形物の製造を可能とする高い加工性を維持しつつ、製品に要求される仕様に応じた良好な物理的特性を有する成形物を製造することができる。このような製造方法によれば、所望の物理的特性を有する成形物を短時間で量産することが可能となるので、本開示の技術の工業的意義は極めて高い。 By mixing an appropriate amount of a second fiber reinforced thermoplastic resin material capable of imparting physical properties such as elastic modulus and strength to the first fiber reinforced thermoplastic resin material having high fluidity, press A molded product having good physical characteristics according to specifications required for a product can be produced while maintaining high workability that enables production of a molded product at a high speed by molding. According to such a manufacturing method, a molded product having desired physical characteristics can be mass-produced in a short time, and therefore, the industrial significance of the technology of the present disclosure is extremely high.
強化材として使用される繊維は、炭素繊維、ガラス繊維、ボロン繊維、アラミド繊維、ポリエチレン繊維、金属繊維、植物繊維などであってもよいが、以下の実施の形態においては、炭素繊維を強化材として使用した例について説明する。 The fiber used as the reinforcing material may be carbon fiber, glass fiber, boron fiber, aramid fiber, polyethylene fiber, metal fiber, vegetable fiber, etc., but in the following embodiment, carbon fiber is used as the reinforcing material. The example used as will be described.
図１は、実施の形態に係る炭素繊維強化熱可塑性樹脂の成形物の製造方法の関連技術について説明するための図である。図１は、ＬＦＴ−Ｄ（Long Fiber Thermoplastics Direct）工法と呼ばれる炭素繊維強化熱可塑性樹脂の成形物の製造方法を模式的に示す。ＬＦＴ−Ｄ工法においては、まず、熱可塑性樹脂原料と添加材を溶融混練することにより製造された熱可塑性樹脂ペレットと、炭素繊維ロービングから供給される炭素繊維とが、二軸スクリュー押出機で混練され、押し出される。押し出されたＬＦＴ−Ｄ押出素材は、高速プレス成形装置に供給されるまでの間、保温・昇温炉において適温に保たれる。保温・昇温炉内のＬＦＴ−Ｄ押出素材は、ロボットアームにより高速プレス成形装置に供給され、所望の形状に成形される。このように、ＬＦＴ−Ｄ工法によれば、熱可塑性樹脂ペレットと炭素繊維を連続的に供給して最終製品を成形するまでの一貫した自動製造システムを構築することが可能となる。また、熱可塑性樹脂を原料としたＬＦＴ−Ｄ押出素材は、流動性及び成形性が高いので、高速プレス成形装置により短時間に所望の形状の最終製品を成形することが可能となる。 Drawing 1 is a figure for explaining the related art of the manufacturing method of the molding of the carbon fiber reinforced thermoplastic resin concerning an embodiment. FIG. 1 schematically shows a method for producing a carbon fiber-reinforced thermoplastic resin molding called an LFT-D (Long Fiber Thermoplastics Direct) method. In the LFT-D method, first, a thermoplastic resin pellet produced by melt-kneading a thermoplastic resin raw material and an additive and a carbon fiber supplied from a carbon fiber roving are kneaded by a twin screw extruder. And pushed out. The extruded LFT-D extruded material is kept at an appropriate temperature in a heat-retaining / heating furnace until it is supplied to a high-speed press molding apparatus. The LFT-D extruded material in the heat-retaining / heating furnace is supplied to a high-speed press forming apparatus by a robot arm and formed into a desired shape. As described above, according to the LFT-D method, it is possible to construct a consistent automatic manufacturing system from the continuous supply of thermoplastic resin pellets and carbon fibers to the molding of the final product. In addition, since the LFT-D extruded material using a thermoplastic resin as a raw material has high fluidity and moldability, a final product having a desired shape can be molded in a short time by a high-speed press molding apparatus.
本発明者らは、図１に示した製造方法により自動車のシャシー部材を成形する実験を行い、従前よりも圧倒的に速い１分程度の時間で成形を完了させることに成功した。また、融着が可能である熱可塑性樹脂の利点を生かし、超音波融着法を用いてシャシー部材を接合することにより、炭素繊維強化熱可塑性樹脂のみによる自動車用シャシーの製作に世界で初めて成功した。 The present inventors conducted an experiment for molding a chassis member of an automobile by the manufacturing method shown in FIG. 1 and succeeded in completing the molding in about 1 minute, which is overwhelmingly faster than before. In addition, taking advantage of the thermoplastic resin that can be fused, we have succeeded in producing the world's first automobile chassis using only carbon fiber reinforced thermoplastic resin by joining the chassis members using the ultrasonic fusion method. did.
本発明者らは、炭素繊維強化熱可塑性樹脂の自動車などの構造部材への応用を更に促進させるために、成形物の物理的特性を更に向上させる技術を検討し、本開示の実施の形態に係る炭素繊維強化熱可塑性樹脂の成形物の製造方法に想到した。 In order to further promote the application of carbon fiber reinforced thermoplastic resin to structural members such as automobiles, the inventors have studied a technique for further improving the physical characteristics of a molded product, and applied the embodiment of the present disclosure. The inventors have come up with a method for producing a molded product of such carbon fiber reinforced thermoplastic resin.
図２は、実施の形態に係る炭素繊維強化熱可塑性樹脂の成形物の製造方法を模式的に示す図である。まず、図１に示したＬＦＴ−Ｄ工法と同様に、二軸スクリュー押出機に、炭素繊維ロービングから供給される炭素繊維と、熱可塑性樹脂のペレットとを原料として供給し、これらを溶融混練して押し出すことにより、第１の繊維強化熱可塑性樹脂素材（以下、単に「第１素材」ともいう）を製造する。つづいて、混練以外の製造方法により製造された第２の繊維熱可塑性樹脂素材（以下、単に「第２素材」ともいう）を、第１素材に混合する。後述するように、第２素材は、例えば、一方向炭素繊維強化熱可塑性樹脂のフレーク（短片）である。混合された第１素材及び第２素材を、流動性が十分に高くなるような温度に加熱し、高速プレス成形装置に導入してプレス成形することにより、所望の形状の成形物を製造する。 Drawing 2 is a figure showing typically the manufacturing method of the molding of the carbon fiber reinforced thermoplastic resin concerning an embodiment. First, similarly to the LFT-D method shown in FIG. 1, carbon fibers supplied from carbon fiber roving and thermoplastic resin pellets are supplied as raw materials to a twin screw extruder, and these are melt-kneaded. To produce a first fiber-reinforced thermoplastic resin material (hereinafter also simply referred to as “first material”). Subsequently, a second fiber thermoplastic resin material (hereinafter also simply referred to as “second material”) manufactured by a manufacturing method other than kneading is mixed with the first material. As will be described later, the second material is, for example, flakes (short pieces) of a unidirectional carbon fiber reinforced thermoplastic resin. The mixed first material and second material are heated to a temperature at which the fluidity becomes sufficiently high, introduced into a high-speed press molding apparatus, and press molded to produce a molded product having a desired shape.
第１素材は、溶融混練押出しにより製造されるので流動性が高く、プレス成形により容易かつ高速に成形物を製造することができる反面、二軸スクリュー押出機において混練される際に炭素繊維が切断されるので、炭素繊維の長さを長くすることにより成形物の弾性率や強度などの物理的特性を向上させるのには一定の限界がある。また、炭素繊維の繊維体積含有率（Ｖｆ）を高くし過ぎると、二軸スクリュー押出機による混練及び押出しが困難になるので、炭素繊維の量を多くすることにより物理的特性を向上させるのにも限界がある。したがって、本実施の形態では、第１素材に含まれる炭素繊維の長さの平均値よりも、第２素材に含まれる炭素繊維の長さの平均値の方が長くなるように調整された第２素材を第１素材に混合することにより、成形物の弾性率や強度などの物理的特性を向上させる。第１素材及び第２素材に含まれる炭素繊維の長さの平均値は、各素材の中心部及び四方の任意の箇所において単位面積（１ｍｍ２）当たりに存在する炭素繊維のそれぞれの長さを、画像測定装置で測定したときの平均値として算出することができる。 Since the first material is manufactured by melt-kneading extrusion, the fluidity is high, and a molded product can be manufactured easily and at high speed by press molding. On the other hand, carbon fibers are cut when kneaded in a twin screw extruder. Therefore, there is a certain limit in improving physical properties such as the elastic modulus and strength of the molded product by increasing the length of the carbon fiber. Also, if the fiber volume content (Vf) of the carbon fiber is too high, kneading and extruding with a twin screw extruder becomes difficult, so physical properties can be improved by increasing the amount of carbon fiber. There is a limit. Therefore, in this Embodiment, it adjusted so that the average value of the length of the carbon fiber contained in a 2nd raw material may become longer than the average value of the length of the carbon fiber contained in a 1st raw material. By mixing the two materials with the first material, physical properties such as elastic modulus and strength of the molded product are improved. The average value of the lengths of the carbon fibers contained in the first material and the second material is the length of each carbon fiber present per unit area (1 mm 2 ) in the central part of each material and in any part of the four sides. It can be calculated as an average value when measured by an image measuring device.
このように、高速なプレス成形を可能とするための流動性及び加工性は主に第１素材により実現され、成形物の弾性率や強度などの物理的特性の更なる向上は主に第２素材により実現される。したがって、本実施の形態の繊維強化熱可塑性樹脂の成形物の製造方法において、第１素材の溶融時の粘度は、第２素材の溶融時の粘度よりも高い。溶融時の粘度は、メルトフローレイト（ＭＦＲ：Melt Mass-Flow Rate）により測定することができる。また、本実施の形態の繊維強化熱可塑性樹脂の成形物の製造方法において、第２素材の繊維体積含有率は、第１素材の繊維体積含有率よりも高い。繊維体積含有率は、日本工業規格ＪＩＳ Ｋ ７０７５−１９９１「炭素繊維強化プラスチックの繊維含有率及び空洞率試験方法」により測定することができる。 As described above, fluidity and workability for enabling high-speed press molding are mainly realized by the first material, and further improvement of physical properties such as elastic modulus and strength of the molding is mainly second. Realized by material. Therefore, in the method for producing a molded product of fiber-reinforced thermoplastic resin according to the present embodiment, the viscosity of the first material when melted is higher than the viscosity of the second material when melted. The viscosity at the time of melting can be measured by a melt flow rate (MFR). Moreover, in the manufacturing method of the molding of the fiber reinforced thermoplastic resin of the present embodiment, the fiber volume content of the second material is higher than the fiber volume content of the first material. The fiber volume content can be measured by Japanese Industrial Standard JIS K 7075-1991 “Testing method for fiber content and void ratio of carbon fiber reinforced plastic”.
第１素材と第２素材の混合比率は、加工物の形状の複雑さや、製品に要求される仕様などに応じて調整されればよい。一般に、第２素材の混合比率が高くなるほど、弾性率や強度などの物理的特性は高くなるが、混合物の加工性は低くなると考えられるので、加工物の形状の複雑さに応じて、混合物の粘度、流動性、加工性を勘案しつつ、製品に要求される仕様に応じて、適切な物理的特性が得られるように、第１素材と第２素材の混合比率を調整してもよい。例えば、高強度・高剛性が要求され、かつ、形状が比較的単純な成形物であれば、第２素材の割合を高くすればよい。また、形状が比較的複雑な成形物であれば、プレス成形の際に高い流動性が要求されるので、第１素材の割合を高くすればよい。 The mixing ratio of the first material and the second material may be adjusted according to the complexity of the shape of the workpiece, the specifications required for the product, and the like. In general, the higher the mixing ratio of the second material, the higher the physical properties such as the modulus of elasticity and strength, but the processability of the mixture is considered to decrease, so depending on the complexity of the shape of the work piece, The mixing ratio of the first material and the second material may be adjusted so as to obtain appropriate physical characteristics according to the specifications required for the product, taking into account the viscosity, fluidity, and workability. For example, if the molded product is required to have high strength and high rigidity and has a relatively simple shape, the ratio of the second material may be increased. In addition, if the molded product has a relatively complicated shape, high fluidity is required during press molding, so the ratio of the first material may be increased.
第２素材に含まれる炭素繊維の長さや、第２素材における炭素繊維の繊維体積含有率についても同様である。一般に、第２素材に含まれる炭素繊維の長さが長いほど、また、第２素材における炭素繊維の繊維体積含有率が高いほど、弾性率や強度などの物理的特性は高くなるが、混合物の加工性は低くなると考えられるので、加工物の形状の複雑さに応じて、混合物の粘度、流動性、加工性を勘案しつつ、製品に要求される仕様に応じて、適切な物理的特性が得られるように、第２素材に含まれる炭素繊維の長さや、第２素材における炭素繊維の繊維体積含有率を調整してもよい。 The same applies to the length of the carbon fibers contained in the second material and the fiber volume content of the carbon fibers in the second material. In general, the longer the carbon fiber contained in the second material and the higher the fiber volume content of the carbon fiber in the second material, the higher the physical properties such as elastic modulus and strength. Since the processability is expected to be low, depending on the complexity of the shape of the work piece, considering the viscosity, fluidity, and workability of the mixture, the appropriate physical properties can be obtained according to the specifications required for the product. As obtained, the length of the carbon fiber contained in the second material and the fiber volume content of the carbon fiber in the second material may be adjusted.
第２素材は、含まれる炭素繊維の長さの平均値が、第１素材に含まれる炭素繊維の長さの平均値よりも長くなるような製造方法であれば、任意の製造方法により製造されてもよいが、第２素材における炭素繊維の繊維体積含有率を高くするためには、炭素繊維に熱可塑性樹脂を含浸させることにより製造された炭素繊維強化熱可塑性樹脂を第２素材として使用するのが好適である。また、製品に要求される仕様に応じて、第２素材に含まれる炭素繊維の長さを調整可能とするためには、一方向に引き揃えた炭素繊維の束又はシートに熱可塑性樹脂を含浸させることにより製造された炭素繊維強化熱可塑性樹脂、又は、炭素繊維を織ったシートに熱可塑性樹脂を含浸させたプリプレグを所定長に切断したフレークを第２素材として使用するのがとくに好適である。 The second material is manufactured by any manufacturing method as long as the average value of the lengths of the carbon fibers included is longer than the average value of the lengths of the carbon fibers included in the first material. However, in order to increase the fiber volume content of the carbon fiber in the second material, a carbon fiber reinforced thermoplastic resin produced by impregnating the carbon fiber with a thermoplastic resin is used as the second material. Is preferred. Also, in order to be able to adjust the length of the carbon fiber contained in the second material according to the specifications required for the product, a bundle of carbon fibers or a sheet aligned in one direction is impregnated with a thermoplastic resin. It is particularly preferable to use, as the second material, a carbon fiber reinforced thermoplastic resin produced by the above process, or a flake obtained by cutting a prepreg obtained by impregnating a thermoplastic fiber into a sheet woven with carbon fiber into a predetermined length. .
第２素材として、均一な長さを有する多数のフレークが使用されてもよい。また、異なる長さを有する複数種類のフレークが使用されてもよいし、長さが所定の範囲に分布した多数のフレークが使用されてもよい。この場合であっても、第２素材に含まれる炭素繊維の長さの平均値は、第１素材に含まれる炭素繊維の長さの平均値よりは長くなるようにする。第２素材に含まれる炭素繊維の長さの平均値は、例えば、５〜１０ｍｍであってもよい。 As the second material, a large number of flakes having a uniform length may be used. Further, a plurality of types of flakes having different lengths may be used, or a large number of flakes having lengths distributed in a predetermined range may be used. Even in this case, the average value of the lengths of the carbon fibers contained in the second material is made longer than the average value of the lengths of the carbon fibers contained in the first material. The average value of the lengths of the carbon fibers contained in the second material may be, for example, 5 to 10 mm.
また、第２素材として、均一な炭素繊維の繊維体積含有率を有する多数のフレークが使用されてもよいし、異なる炭素繊維の繊維体積含有率を有する複数種類のフレークが使用されてもよいし、炭素繊維の繊維体積含有率が所定の範囲に分布した多数のフレークが使用されてもよい。 Further, as the second material, a large number of flakes having a uniform fiber volume content of carbon fibers may be used, or a plurality of types of flakes having a fiber volume content of different carbon fibers may be used. A large number of flakes in which the fiber volume content of carbon fibers is distributed in a predetermined range may be used.
第２素材は、針状、フレーク状、短冊状、線状、棒状の形状を有していてもよいし、その他の任意の二次元形状又は三次元形状を有していてもよい。 The second material may have a needle shape, a flake shape, a strip shape, a line shape, a rod shape, or any other two-dimensional shape or three-dimensional shape.
第１素材及び第２素材の母材となる熱可塑性樹脂は、例えば、ポリアミド６、ポリアミド１１、ポリアミド１２、ポリアミド６６、ポリアミド６１０、ポリアミド６Ｔ、ポリアミド６Ｉ、ポリアミド９Ｔ、ポリアミドＭ５Ｔなどのポリアミド、ポリエチレン、ポリプロピレン、ポリ塩化ビニル、ポリ塩化ビニリデン、ポリスチレン、ポリ酢酸ビニル、ポリウレタン、ポリテトラフルオロエチレン、アクリロニトリルブタジエンスチレン、アクリル樹脂、ポリアセタール、ポリカーボネート、ポリフェニレンエーテル、変性ポリフェニレンエーテル、ポリエステル、ポリエチレンテレフタレート、ポリブチレンテレフタレート、環状ポリオレフィン、ポリフェニレンスルファイド、ポリスルホン、ポリエーテルスルホン、ポリエーテルエーテルケトン、ポリイミド、ポリアミドイミドなどであってもよい。 The thermoplastic resin used as the base material of the first material and the second material is, for example, polyamide 6, polyethylene such as polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 610, polyamide 6T, polyamide 6I, polyamide 9T, polyamide M5T, or the like. , Polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, polyurethane, polytetrafluoroethylene, acrylonitrile butadiene styrene, acrylic resin, polyacetal, polycarbonate, polyphenylene ether, modified polyphenylene ether, polyester, polyethylene terephthalate, polybutylene terephthalate , Cyclic polyolefin, polyphenylene sulfide, polysulfone, polyethersulfone, polyetherether Tons, polyimide, or the like may be used polyamideimide.
第１素材の母材となる熱可塑性樹脂と、第２素材の母材となる熱可塑性樹脂は、同種の熱可塑性樹脂であることが好ましい。これにより、成形物の全体を同種の熱可塑性樹脂を母材とする炭素繊維強化熱可塑性樹脂により形成することができるので、第１素材と第２素材との境界面から破断したり、反りが生じたりするのを防ぐことができ、成形物の強度や剛性などの物理的特性を向上させることができる。異種の熱可塑性樹脂であっても、融点や熱膨張率などの物理的性質が類似する熱可塑性樹脂の組合せや、相溶性を有する熱可塑性樹脂の組合せや、境界面が生じたとしても境界面における接着性が良好である熱可塑性樹脂の組合せなどを母材とする第１素材と第２素材が混合されてもよい。 The thermoplastic resin that is the base material of the first material and the thermoplastic resin that is the base material of the second material are preferably the same kind of thermoplastic resin. As a result, the entire molded product can be formed of a carbon fiber reinforced thermoplastic resin having the same kind of thermoplastic resin as a base material, so that it can be broken or warped from the boundary surface between the first material and the second material. Can be prevented, and physical properties such as strength and rigidity of the molded product can be improved. Even if different types of thermoplastic resins are used, the combination of thermoplastic resins with similar physical properties such as melting point and thermal expansion coefficient, compatible thermoplastic resins, The first material and the second material having a base material of a combination of thermoplastic resins having good adhesiveness may be mixed.
第１素材及び第２素材は、それぞれ、複数の種類の熱可塑性樹脂を母材として含むポリマーブレンドであってもよい。この場合も、それぞれが同種の熱可塑性樹脂を母材として含んでいるのが好ましく、また、ポリマーブレンドの組成比が同程度であることが好ましい。 Each of the first material and the second material may be a polymer blend including a plurality of types of thermoplastic resins as a base material. Also in this case, it is preferable that each of them contains the same kind of thermoplastic resin as a base material, and it is preferable that the composition ratio of the polymer blend is approximately the same.
第１素材と第２素材を混合する方法として、例えば、以下の第１〜３の方法が考えられる。第１の方法は、第２素材を第１素材の表面にまぶす方法である。第１素材の上方から第２素材を散布してもよい。第１素材の上面だけでなく、裏面や側面にも第２素材をまぶす場合には、第１素材を回転させて別の面を上面とし、上方から第２素材を散布してもよいし、第１素材の裏面又は側面から第２素材を吹き付けてもよい。製品に要求される仕様に応じて、多数の第２素材の長手方向が揃うように第１素材の表面にまぶしてもよいし、ランダムな方向になるように第１素材の表面にまぶしてもよい。第１の方法によれば、第１素材の表面に第２素材の層を形成することができるので、成形物の表面層の強度や剛性などの物理的特性を向上させることができる。また、簡易な方法で第１素材に第２素材を混合することができるので、設備のコストを抑えることができる。 As a method of mixing the first material and the second material, for example, the following first to third methods can be considered. The first method is a method in which the second material is applied to the surface of the first material. The second material may be sprayed from above the first material. When the second material is applied not only to the upper surface of the first material but also to the back surface and the side surface, the first material may be rotated to make another surface the upper surface, and the second material may be sprayed from above. The second material may be sprayed from the back surface or the side surface of the first material. Depending on the specifications required for the product, it may be applied to the surface of the first material so that the longitudinal directions of many second materials are aligned, or may be applied to the surface of the first material so as to be in a random direction. Good. According to the first method, since the layer of the second material can be formed on the surface of the first material, physical characteristics such as strength and rigidity of the surface layer of the molded product can be improved. Moreover, since a 2nd raw material can be mixed with a 1st raw material by a simple method, the cost of an installation can be held down.
第２の方法は、第２素材によりシートを成形し、成形したシートを第１素材に被せる方法である。第２素材のシートは、例えば、第２素材を平面上に散布して加熱及び加圧することにより成形されてもよい。第２素材のシートを、第１素材の表面の全てを覆うように被せてもよいし、上面と裏面を覆うように被せてもよいし、一部の表面のみを覆うように被せてもよい。この場合も、製品に要求される仕様に応じて、多数の第２素材の長手方向が揃うようにシートを成形してもよいし、ランダムな方向になるようにシートを成形してもよい。第２の方法によれば、第１素材の表面に均一な第２素材の層を形成することができるので、第２素材の分布ムラを防ぎ、良好な物理的特性を有する成形物を製造することができる。 The second method is a method in which a sheet is formed from the second material, and the formed sheet is placed on the first material. The sheet of the second material may be formed, for example, by spraying the second material on a flat surface and heating and pressing. The sheet of the second material may be covered so as to cover the entire surface of the first material, may be covered so as to cover the upper surface and the back surface, or may be covered so as to cover only a part of the surface. . Also in this case, according to the specifications required for the product, the sheet may be formed so that the longitudinal directions of a large number of second materials are aligned, or the sheet may be formed so as to be in a random direction. According to the second method, since a uniform second material layer can be formed on the surface of the first material, uneven distribution of the second material is prevented, and a molded product having good physical characteristics is manufactured. be able to.
第３の方法は、第１素材の内部に第２素材を注入する方法である。多数の第２素材を集積して連続的な流れとし、これを第１素材が排出される前又は後に注入してもよい。第３の方法によれば、成形物の内部の弾性率や強度も向上させることができる。 The third method is a method of injecting the second material into the first material. A large number of second materials may be accumulated to form a continuous flow, which may be injected before or after the first material is discharged. According to the 3rd method, the elasticity modulus and intensity | strength inside a molded object can also be improved.
第１及び第２の方法で第１素材と第２素材を混合する場合は、成形物の表面層は主に第２素材により形成され、成形物の内部は主に第１素材により形成されることになるので、成形物の表面層を構成する繊維強化熱可塑性樹脂に含まれる繊維の長さの平均値は、成形物の内部を構成する繊維強化熱可塑性樹脂に含まれる繊維の長さの平均値よりも長くなる。これにより、成形物の表面層の弾性率や強度などの物理的特性を向上させることができる。 When the first material and the second material are mixed by the first and second methods, the surface layer of the molded product is mainly formed by the second material, and the inside of the molded product is mainly formed by the first material. Therefore, the average value of the length of the fibers contained in the fiber reinforced thermoplastic resin constituting the surface layer of the molded product is the length of the fibers contained in the fiber reinforced thermoplastic resin constituting the inside of the molded product. It becomes longer than the average value. Thereby, physical characteristics, such as an elasticity modulus and intensity | strength of the surface layer of a molded object, can be improved.
図３は、実施の形態に係る炭素繊維強化熱可塑性樹脂の成形物の製造方法の別の例を模式的に示す図である。図２に示した例では、第２素材を製品として購入し、第１素材に混合することを想定していたが、図３に示した例では、第１素材と第２素材を並行して製造し、両者を混合する。 Drawing 3 is a figure showing typically another example of the manufacturing method of the molding of a carbon fiber reinforced thermoplastic resin concerning an embodiment. In the example shown in FIG. 2, it is assumed that the second material is purchased as a product and mixed with the first material. However, in the example shown in FIG. 3, the first material and the second material are mixed in parallel. Manufacture and mix both.
フレーク製造装置において、炭素繊維ロービングから供給される炭素繊維に熱可塑性樹脂を含浸させ、所定長に切断することにより、第２素材を製造する。熱可塑性樹脂のモノマーを炭素繊維に含浸させた後、加熱して重合させれば、ポリマーを炭素繊維に含浸させる場合と異なり、含浸のために高温及び高圧を発生させる必要がないので、とくに好適である。 In the flake manufacturing apparatus, carbon fiber supplied from carbon fiber roving is impregnated with a thermoplastic resin and cut into a predetermined length to manufacture the second material. When carbon fiber is impregnated with a thermoplastic resin monomer and then heated and polymerized, unlike the case where carbon fiber is impregnated with polymer, it is not particularly necessary to generate high temperature and high pressure for impregnation. It is.
このような現場重合型の炭素繊維強化熱可塑性樹脂の製造においては、ε−カプロラクタムをモノマーとするポリアミドを使用するのがとくに好適である。ε−カプロラクタムの融点は６９℃と低く、融解させた液体の粘度も十分に低いので、炭素繊維に容易に含浸させることができる。また、重合反応に要する温度が比較的低く、重合反応に要する時間も極めて短いので、フレーク製造装置において連続的に含浸、重合、切断を行い、効率良く第２素材を製造することができる。 In the production of such an in-situ polymerization type carbon fiber reinforced thermoplastic resin, it is particularly preferable to use a polyamide having ε-caprolactam as a monomer. Since the melting point of ε-caprolactam is as low as 69 ° C. and the viscosity of the melted liquid is sufficiently low, the carbon fiber can be easily impregnated. In addition, since the temperature required for the polymerization reaction is relatively low and the time required for the polymerization reaction is extremely short, the second material can be efficiently manufactured by continuously impregnating, polymerizing, and cutting in the flake manufacturing apparatus.
図３の例によれば、炭素繊維ロービングから供給される炭素繊維を、第１素材の原料としても、第２素材の原料としても使用することができるので、廃材が極めて少ない製造方法を実現することができる。また、第１素材と第２素材を同時に並行して製造するので、製造した第１素材と第２素材を高温のまますぐに混合し、高速プレス成形装置に導入して成形することができる。したがって、省エネルギーかつ省スペースの製造ラインを実現することができる。これらの点においても、本開示の技術の工業的意義は極めて高い。 According to the example of FIG. 3, the carbon fiber supplied from the carbon fiber roving can be used as the raw material of the first material as well as the raw material of the second material, thereby realizing a manufacturing method with very little waste material. be able to. Further, since the first material and the second material are manufactured in parallel at the same time, the manufactured first material and the second material can be immediately mixed at a high temperature and introduced into a high-speed press molding apparatus for molding. Therefore, an energy-saving and space-saving production line can be realized. Also in these points, the industrial significance of the technology of the present disclosure is extremely high.
図４は、実施の形態に係るフレーク製造装置の構成を模式的に示す図である。図３に示したように、第１素材と第２素材を同時に並行して製造し、それらの混合物をプレス成形して成形物を高速に量産する場合には、第２素材も高速に製造する必要がある。図４に示したフレーク製造装置１０は、熱可塑性樹脂を含浸した一方向シート又は多数のトウを高速で製造し、それを切断することにより、第２素材として使用可能な一方向炭素繊維強化熱可塑性樹脂フレークを高速かつ大量に製造する。 FIG. 4 is a diagram schematically showing the configuration of the flake manufacturing apparatus according to the embodiment. As shown in FIG. 3, when the first material and the second material are manufactured in parallel at the same time, and the mixture is press-molded to mass-produce the molded product, the second material is also manufactured at a high speed. There is a need. The flake production apparatus 10 shown in FIG. 4 produces a unidirectional carbon fiber reinforced heat usable as a second material by producing a unidirectional sheet or a large number of tows impregnated with a thermoplastic resin at a high speed and cutting it. High-speed and large-scale production of plastic resin flakes.
フレーク製造装置１０は、熱可塑性樹脂のモノマーの液体を炭素繊維２０に含浸させるための含浸チャンバー１１と、熱可塑性樹脂のモノマーを含浸させた炭素繊維２０を加熱してモノマーを重合させるための重合チャンバー１４と、熱可塑性樹脂のポリマーが含浸した炭素繊維２０を切断する切断部１５と、炭素繊維２０をフレーク製造装置１０に導入し、チャンバー内及びチャンバー間で移動させ、フレーク製造装置１０から引き出すための移動部１６とを備える。 The flake production apparatus 10 includes an impregnation chamber 11 for impregnating the carbon fiber 20 with a liquid of a thermoplastic resin monomer, and a polymerization for polymerizing the monomer by heating the carbon fiber 20 impregnated with the thermoplastic resin monomer. The chamber 14, the cutting portion 15 for cutting the carbon fiber 20 impregnated with the polymer of the thermoplastic resin, and the carbon fiber 20 are introduced into the flake production apparatus 10, moved between the chambers and between the chambers, and pulled out from the flake production apparatus 10. And a moving unit 16 for the purpose.
含浸チャンバー１１には、炭素繊維ロービングから供給される炭素繊維２０を通すための、分割された複数の通路１２が設けられる。含浸チャンバー１１の上方に、ε−カプロラクタムの液体を散布するための配管１３が設けられ、融点以上に加熱されたε−カプロラクタムの液体が、配管１３に設けられた吐出口から炭素繊維２０に散布される。ε−カプロラクタムの液体が炭素繊維２０に含浸するのに十分な時間が経過すると、移動部１６により、ε−カプロラクタムが含浸した部分が重合チャンバー１４内に入るように炭素繊維２０を移動させる。 The impregnation chamber 11 is provided with a plurality of divided passages 12 for passing the carbon fibers 20 supplied from the carbon fiber roving. A pipe 13 for spraying ε-caprolactam liquid is provided above the impregnation chamber 11, and the ε-caprolactam liquid heated to the melting point or higher is sprayed to the carbon fiber 20 from the discharge port provided in the pipe 13. Is done. When a sufficient time has elapsed for the carbon fiber 20 to be impregnated with the liquid of ε-caprolactam, the moving portion 16 moves the carbon fiber 20 so that the portion impregnated with ε-caprolactam enters the polymerization chamber 14.
重合チャンバー１４には、ε−カプロラクタムの重合反応を開始・促進させるために必要な温度に加温するための加熱部が設けられる。ε−カプロラクタムが重合してポリアミド６が生成されるのに十分な時間が経過すると、移動部１６により、ポリアミド６が含浸した炭素繊維２０を切断部１５へ移動させる。 The polymerization chamber 14 is provided with a heating unit for heating to a temperature necessary for initiating and promoting the polymerization reaction of ε-caprolactam. When a sufficient time has elapsed for ε-caprolactam to be polymerized to produce polyamide 6, carbon fiber 20 impregnated with polyamide 6 is moved to cutting unit 15 by moving unit 16.
含浸チャンバー１１において含浸に必要な時間と、重合チャンバー１４において重合に必要な時間とに応じて、含浸チャンバー１１の経路の長さ、重合チャンバー１４の経路の長さ、移動部１６による炭素繊維２０の移動速度が調整されてもよい。例えば、移動部１６が一定の速度で炭素繊維２０を移動させたときに、含浸チャンバー１１における滞在時間が含浸に必要な時間よりも長くなり、重合チャンバー１４における滞在時間が重合に必要な時間よりも長くなるように、含浸チャンバー１１の経路の長さ、重合チャンバー１４の経路の長さ、移動部１６による炭素繊維２０の移動速度が調整されてもよい。 Depending on the time required for impregnation in the impregnation chamber 11 and the time required for polymerization in the polymerization chamber 14, the length of the path of the impregnation chamber 11, the length of the path of the polymerization chamber 14, the carbon fiber 20 by the moving unit 16. The moving speed may be adjusted. For example, when the moving unit 16 moves the carbon fiber 20 at a constant speed, the residence time in the impregnation chamber 11 is longer than the time required for impregnation, and the residence time in the polymerization chamber 14 is longer than the time required for polymerization. Also, the length of the path of the impregnation chamber 11, the length of the path of the polymerization chamber 14, and the moving speed of the carbon fiber 20 by the moving unit 16 may be adjusted so as to be longer.
切断部１５は、ポリアミド６が含浸した炭素繊維２０を所定長ごとに切断して、所定長のフレーク２１を製造する。切断部１５は一定の間隔で炭素繊維２０を切断し、炭素繊維２０が所定長ごとに切断されるように移動部１６が炭素繊維２０の移動速度を調整してもよいし、移動部１６は一定の速度で炭素繊維２０を移動させ、炭素繊維２０が所定長ごとに切断されるように切断部１５が切断する間隔を調整してもよい。 The cutting part 15 cuts the carbon fiber 20 impregnated with the polyamide 6 into predetermined lengths to produce flakes 21 having a predetermined length. The cutting unit 15 may cut the carbon fiber 20 at regular intervals, and the moving unit 16 may adjust the moving speed of the carbon fiber 20 so that the carbon fiber 20 is cut every predetermined length. You may adjust the space | interval which the cutting part 15 cut | disconnects so that the carbon fiber 20 may be moved at a fixed speed and the carbon fiber 20 may be cut | disconnected for every predetermined length.
含浸チャンバー１１と重合チャンバー１４は同じチャンバーにより実現されてもよい。この場合、炭素繊維２０をチャンバー内に引き入れ、ε−カプロラクタムの液体を散布して炭素繊維２０に含浸させ、チャンバー内を加熱してε−カプロラクタムを重合させ、炭素繊維２０をチャンバーから引き出して所定長に切断するという工程を繰り返してもよい。 The impregnation chamber 11 and the polymerization chamber 14 may be realized by the same chamber. In this case, the carbon fiber 20 is drawn into the chamber, a liquid of ε-caprolactam is sprayed to impregnate the carbon fiber 20, the inside of the chamber is heated to polymerize ε-caprolactam, and the carbon fiber 20 is pulled out of the chamber to be predetermined. You may repeat the process of cut | disconnecting long.
含浸チャンバー１１及び重合チャンバー１４に、複数の炭素繊維２０を通すための通路１２を設けておくことにより、隣接する炭素繊維２０同士が、含浸した熱可塑性樹脂により接着してしまうのを防ぐことができる。熱可塑性樹脂が含浸した炭素繊維のシートを製造する場合には、通路１２は設けられなくてもよい。通路１２を設けない含浸チャンバー１１及び重合チャンバー１４により、熱可塑性樹脂が含浸した炭素繊維２０を製造した後、所定の幅に切断することにより、複数の一方向炭素繊維強化熱可塑性樹脂のトウを製造してもよい。 By providing the impregnation chamber 11 and the polymerization chamber 14 with a passage 12 for passing a plurality of carbon fibers 20, it is possible to prevent the adjacent carbon fibers 20 from being bonded to each other by the impregnated thermoplastic resin. it can. In the case of producing a carbon fiber sheet impregnated with a thermoplastic resin, the passage 12 may not be provided. After the carbon fiber 20 impregnated with the thermoplastic resin is produced by the impregnation chamber 11 and the polymerization chamber 14 without the passage 12, the tow of a plurality of unidirectional carbon fiber reinforced thermoplastic resins is cut by cutting to a predetermined width. It may be manufactured.
含浸チャンバー１１及び重合チャンバー１４の通路１２の長さ、数、及び幅は、後続の高速プレス成形装置に供給する第２素材の時間当たりの量に応じて調整されればよい。 The length, number, and width of the passage 12 of the impregnation chamber 11 and the polymerization chamber 14 may be adjusted according to the amount of the second material supplied to the subsequent high-speed press molding apparatus per hour.
フレーク製造装置は、本開示に係る繊維強化熱可塑性樹脂の製造装置の一例であり、比較的短い繊維強化熱可塑性樹脂のフレークを製造するためのものであるが、比較的長い繊維強化熱可塑性樹脂のトウやシートなどを製造することも可能である。また、炭素繊維ロービングなどの形で提供される炭素繊維以外にも、各種繊維のモノフィラメント、マルチフィラメントなど、所定以上の長さを有する連続した長繊維に熱可塑性樹脂を効率良く含浸させ、繊維強化熱可塑性樹脂のフレーク、トウ、シートなどを製造することも可能である。 The flake manufacturing apparatus is an example of a fiber reinforced thermoplastic resin manufacturing apparatus according to the present disclosure, and is for manufacturing relatively short fiber reinforced thermoplastic resin flakes, but a relatively long fiber reinforced thermoplastic resin. It is also possible to manufacture tows and sheets. In addition to carbon fibers provided in the form of carbon fiber rovings, etc., continuous filaments with various lengths such as monofilaments and multifilaments of various fibers are efficiently impregnated with a thermoplastic resin to strengthen the fibers. It is also possible to produce thermoplastic resin flakes, tows, sheets and the like.
以上、本開示を実施例をもとに説明した。この実施例は例示であり、それらの各構成要素や各処理プロセスの組合せにいろいろな変形例が可能なこと、またそうした変形例も本開示の範囲にあることは当業者に理解されるところである。 The present disclosure has been described based on the embodiments. This embodiment is an exemplification, and it will be understood by those skilled in the art that various modifications can be made to the combination of each component and each processing process, and such modifications are within the scope of the present disclosure. .
本開示の一態様の概要は、次の通りである。本開示のある態様の繊維強化熱可塑性樹脂の製造方法は、複数の長繊維をチャンバー内に導入するステップと、チャンバー内で長繊維に熱可塑性樹脂のモノマーの液体又は溶液を含浸させるステップと、モノマーが含浸された長繊維を加熱することによりモノマーを重合させるステップと、熱可塑性樹脂が含浸された長繊維をチャンバーから引き出すステップと、を備える。 The outline | summary of 1 aspect of this indication is as follows. A method for producing a fiber-reinforced thermoplastic resin according to an aspect of the present disclosure includes a step of introducing a plurality of long fibers into a chamber, and a step of impregnating a long fiber into a liquid or solution of a monomer of a thermoplastic resin in the chamber; Heating the long fiber impregnated with the monomer to polymerize the monomer, and pulling out the long fiber impregnated with the thermoplastic resin from the chamber.
この態様によると、熱可塑性樹脂が均一に含浸した良好な物理的特性を有する繊維強化熱可塑性樹脂を短時間で製造することができる。 According to this aspect, a fiber-reinforced thermoplastic resin having good physical properties uniformly impregnated with a thermoplastic resin can be produced in a short time.
この繊維強化熱可塑性樹脂の製造方法は、熱可塑性樹脂が含浸された長繊維を所定長に切断するステップを更に備えてもよい。この態様によると、良好な物理的特性を有する繊維強化熱可塑性樹脂のフレークを短時間で製造することができる。 The method for producing a fiber-reinforced thermoplastic resin may further include a step of cutting the long fiber impregnated with the thermoplastic resin into a predetermined length. According to this aspect, flakes of fiber reinforced thermoplastic resin having good physical properties can be produced in a short time.
この繊維強化熱可塑性樹脂の製造方法において、長繊維は、一方向に引き揃えた複数の炭素繊維であってもよい。この態様によると、良好な物理的特性を有する繊維強化熱可塑性樹脂を連続的に短時間で製造することができる。 In this method for producing a fiber-reinforced thermoplastic resin, the long fibers may be a plurality of carbon fibers arranged in one direction. According to this aspect, a fiber reinforced thermoplastic resin having good physical properties can be continuously produced in a short time.
この繊維強化熱可塑性樹脂の製造方法において、モノマーは、ε−カプロラクタムであってもよい。この態様によると、熱可塑性樹脂を高速かつ均一に繊維に含浸させることができる。 In this method for producing a fiber-reinforced thermoplastic resin, the monomer may be ε-caprolactam. According to this aspect, the fiber can be impregnated with the thermoplastic resin at high speed and uniformly.
本開示の別の態様は、繊維強化熱可塑性樹脂の製造装置である。この装置は、複数の長繊維に熱可塑性樹脂のモノマーの液体又は溶液を含浸させるための含浸チャンバーと、モノマーが含浸された長繊維を加熱することによりモノマーを重合させるための重合チャンバーと、熱可塑性樹脂が含浸された長繊維を重合チャンバーから引き出すための移動部と、を備える。 Another aspect of the present disclosure is an apparatus for manufacturing a fiber-reinforced thermoplastic resin. The apparatus includes an impregnation chamber for impregnating a plurality of long fibers with a liquid or solution of a monomer of a thermoplastic resin, a polymerization chamber for polymerizing the monomers by heating the long fibers impregnated with the monomers, And a moving part for pulling out the long fiber impregnated with the plastic resin from the polymerization chamber.
この態様によると、熱可塑性樹脂が均一に含浸した良好な物理的特性を有する繊維強化熱可塑性樹脂を短時間で製造することができる。 According to this aspect, a fiber-reinforced thermoplastic resin having good physical properties uniformly impregnated with a thermoplastic resin can be produced in a short time.
この繊維強化熱可塑性樹脂の製造装置において、含浸チャンバー及び重合チャンバーは、複数の長繊維をそれぞれ通すための複数の通路を備えてもよい。この態様によると、隣接する長繊維同士が、含浸した熱可塑性樹脂により接着してしまうのを防ぐことができる。 In this fiber reinforced thermoplastic resin manufacturing apparatus, the impregnation chamber and the polymerization chamber may include a plurality of passages for allowing a plurality of long fibers to pass therethrough. According to this aspect, adjacent long fibers can be prevented from being bonded by the impregnated thermoplastic resin.
この繊維強化熱可塑性樹脂の製造装置において、熱可塑性樹脂が含浸された長繊維を所定長に切断する切断部を更に備えてもよい。この態様によると、良好な物理的特性を有する繊維強化熱可塑性樹脂のフレークを短時間で製造することができる。 The fiber-reinforced thermoplastic resin manufacturing apparatus may further include a cutting unit that cuts the long fiber impregnated with the thermoplastic resin into a predetermined length. According to this aspect, flakes of fiber reinforced thermoplastic resin having good physical properties can be produced in a short time.
この繊維強化熱可塑性樹脂の製造装置において、長繊維は、一方向に引き揃えた複数の炭素繊維であってもよい。この態様によると、良好な物理的特性を有する繊維強化熱可塑性樹脂を連続的に短時間で製造することができる。 In the fiber-reinforced thermoplastic resin manufacturing apparatus, the long fibers may be a plurality of carbon fibers aligned in one direction. According to this aspect, a fiber reinforced thermoplastic resin having good physical properties can be continuously produced in a short time.
この繊維強化熱可塑性樹脂の製造装置において、モノマーは、ε−カプロラクタムであってもよい。この態様によると、熱可塑性樹脂を高速かつ均一に繊維に含浸させることができる。 In this fiber-reinforced thermoplastic resin production apparatus, the monomer may be ε-caprolactam. According to this aspect, the fiber can be impregnated with the thermoplastic resin at high speed and uniformly.
１０ フレーク製造装置、１１ 含浸チャンバー、１２ 通路、１３ 配管、１４ 重合チャンバー、１５ 切断部、１６ 移動部、２０ 炭素繊維、２１ フレーク。 10 flake production equipment, 11 impregnation chamber, 12 passage, 13 piping, 14 polymerization chamber, 15 cutting part, 16 moving part, 20 carbon fiber, 21 flake.
Claims (9)
前記チャンバー内で前記長繊維に熱可塑性樹脂のモノマーの液体又は溶液を含浸させるステップと、
前記モノマーが含浸された前記長繊維を加熱することにより前記モノマーを重合させるステップと、
前記熱可塑性樹脂が含浸された前記長繊維を前記チャンバーから引き出すステップと、
を備えることを特徴とする繊維強化熱可塑性樹脂の製造方法。 Introducing a plurality of long fibers into the chamber;
Impregnating the long fiber in the chamber with a liquid or solution of a monomer of a thermoplastic resin;
Polymerizing the monomer by heating the filaments impregnated with the monomer; and
Withdrawing the long fibers impregnated with the thermoplastic resin from the chamber;
A process for producing a fiber-reinforced thermoplastic resin, comprising:
前記モノマーが含浸された前記長繊維を加熱することにより前記モノマーを重合させるための重合チャンバーと、
前記熱可塑性樹脂が含浸された前記長繊維を前記重合チャンバーから引き出すための移動部と、
を備えることを特徴とする繊維強化熱可塑性樹脂の製造装置。 An impregnation chamber for impregnating a plurality of long fibers with a liquid or solution of a monomer of a thermoplastic resin;
A polymerization chamber for polymerizing the monomer by heating the long fibers impregnated with the monomer;
A moving part for pulling out the long fibers impregnated with the thermoplastic resin from the polymerization chamber;
An apparatus for producing a fiber-reinforced thermoplastic resin, comprising:
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| JPH03130112A (en) * | 1989-07-07 | 1991-06-03 | Ube Nitto Kasei Co Ltd | Production of fiber reinforced polyamide resin composition |
| JPH03132338A (en) * | 1989-10-18 | 1991-06-05 | Kobe Steel Ltd | Continuous preparation of long structural material made of fiber |
| JPH04249538A (en) * | 1990-12-28 | 1992-09-04 | Ube Nitto Kasei Co Ltd | Glass-reinforced polyamide resin composition and production thereof |
| JPH05309751A (en) * | 1991-11-28 | 1993-11-22 | Monsanto Europe Sa | Nylon pultrusion process |
| US5424388A (en) * | 1993-06-24 | 1995-06-13 | Industrial Technology Research Institute | Pultrusion process for long fiber-reinforced nylon composites |
| JP2005513206A (en) * | 2001-12-20 | 2005-05-12 | エムス−ヒェミー アクチェンゲゼルシャフト | Method for producing a composite material using a thermoplastic matrix |
| US20140154937A1 (en) * | 2012-12-04 | 2014-06-05 | Basf Se | Process for the production of a fiber-reinforced composite material |
| US20150011706A1 (en) * | 2009-06-02 | 2015-01-08 | Johns Manville | Methods and systems for making reinforced thermoplastic composites, and the products |
| JP2017007266A (en) * | 2015-06-25 | 2017-01-12 | 学校法人日本大学 | Pultrusion manufacturing equipment of fiber-reinforced polyamide composite material, and pultrusion manufacturing method |
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- 2019-02-08 JP JP2019021862A patent/JP2019147945A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH03130112A (en) * | 1989-07-07 | 1991-06-03 | Ube Nitto Kasei Co Ltd | Production of fiber reinforced polyamide resin composition |
| JPH03132338A (en) * | 1989-10-18 | 1991-06-05 | Kobe Steel Ltd | Continuous preparation of long structural material made of fiber |
| JPH04249538A (en) * | 1990-12-28 | 1992-09-04 | Ube Nitto Kasei Co Ltd | Glass-reinforced polyamide resin composition and production thereof |
| JPH05309751A (en) * | 1991-11-28 | 1993-11-22 | Monsanto Europe Sa | Nylon pultrusion process |
| US5424388A (en) * | 1993-06-24 | 1995-06-13 | Industrial Technology Research Institute | Pultrusion process for long fiber-reinforced nylon composites |
| JP2005513206A (en) * | 2001-12-20 | 2005-05-12 | エムス−ヒェミー アクチェンゲゼルシャフト | Method for producing a composite material using a thermoplastic matrix |
| US20150011706A1 (en) * | 2009-06-02 | 2015-01-08 | Johns Manville | Methods and systems for making reinforced thermoplastic composites, and the products |
| US20140154937A1 (en) * | 2012-12-04 | 2014-06-05 | Basf Se | Process for the production of a fiber-reinforced composite material |
| JP2017007266A (en) * | 2015-06-25 | 2017-01-12 | 学校法人日本大学 | Pultrusion manufacturing equipment of fiber-reinforced polyamide composite material, and pultrusion manufacturing method |
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