JP2650349B2 - Laminated structure and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial application field) The present invention is to provide a laminated structure for providing various molded articles having a uniform thickness, and in particular, compression molded articles. The present invention relates to a method for manufacturing a laminated structure that stably provides a laminated structure.

(Prior art) Conventionally, a sheet-like material (hereinafter, referred to as a prepreg) in which a thermosetting resin is impregnated or coated with a synthetic fiber cloth or the like is cut into a specific plane shape, and a plurality of sheets are assembled into a predetermined phase and three-dimensionally molded. However, the uniformity of such a molded article depends on the skill of a molding operator at the time of assembly.

(Problems to be Solved by the Present Invention) Usually, when forming a fabric laminate, particularly in the case of compression molding, a prepreg is preliminarily assembled with a certain phase in each layer (hereinafter referred to as a preform), This preform product is charged into a mold or clamped and molded by heating. However, with this charge, there is a disadvantage that the mutual positions (phases) between the fabrics of the respective layers are displaced during mold clamping, so that a uniform laminate cannot be obtained. This trend is
In particular, molding into a complicated shape such as a three-dimensional curved body is extremely large, and improvement has been urgently needed.

The present invention provides a laminated structure capable of providing a uniform molded product without a phase shift even in a preform of a three-dimensional molded product such as a three-dimensional curved body, and further provides such a laminated structure. Is provided stably and efficiently.

(Means for Solving the Problems) The present invention employs the following means to solve the problems. That is, in the laminate structure of the present invention, in a laminate made of a fiber cloth containing a synthetic resin mixture of a thermoplastic resin and a thermosetting resin, the fiber cloths are partially positioned by heat fusion. In addition, the method for manufacturing such a laminated structure is characterized in that a plurality of fiber fabrics impregnated with a synthetic resin mixture of a thermoplastic resin and a thermosetting resin are laminated, and then partially heat-treated. Then, the thermoplastic resin is melted to position the fiber cloths.

Examples of the fibers applied to the present invention include fibers made of polymers such as nylon, polyester, polyurethane, polyacrylonitrile, polypropylene, vinylon, aromatic polyamide, high-strength polyethylene, high-strength polyvinyl alcohol, and high-strength acrylonitrile, and fluorine fibers, Carbon fiber, glass fiber, and metal fiber.

As a fabric made of such fibers, for example, a sheet material such as a woven fabric, a knitted fabric, or a nonwoven fabric can be applied.

In the present invention, a mixture of two kinds of synthetic resins, a thermoplastic resin and a thermosetting resin, is applied from the viewpoint of fusing property and form stability.

The thermoplastic resin of the present invention has a function of positioning (phase) between fabrics by fusing adjacent layers,
Not only those having plasticity and adhesiveness but also those which react with a thermosetting component by heating to form a copolymer may be used. Such thermoplastic resins include, for example, polyamide resins, polyester resins, polyurethane resins,
Examples include methacrylic resin and polyvinyl butyral resin.

Examples of the thermosetting resin include an unsaturated polyester resin, a crosslinkable polyurethane resin, an epoxy resin, a phenol resin, a vinyl ester resin, a urea resin, a melamine resin, and a polyimide resin.

Such a thermoplastic resin and a thermosetting resin are mixed by selecting at least one from each resin group. As a mixed resin composition, a particularly preferred combination is a polyvinyl butyral resin and a phenol resin, and the mixed resin composition has excellent prepreg workability and fusion characteristics.

The mixing ratio of the thermoplastic resin / thermosetting resin is selected depending on the characteristics of the applied resin and the purpose of use of the molded article, but is preferably 20/80 to 70/30, more preferably 40/60 to 60/40. Adopt a range. When the thermoplastic resin content is 20% or less, the fusibility tends to decrease, and when the thermoplastic resin content exceeds 70%, the moldability tends to deteriorate.

The weight ratio of synthetic fiber / synthetic resin is determined depending on the purpose of use of the molded article, but is preferably 5/95 to 50/50, and more preferably 1/95 to 50/50.
It is selected from the range of 0/90 to 40/60.

The prepreg sheet of the present invention is formed by a general method such as a solution impregnation method or a coating method.

The prepreg of the present invention is characterized in that the synthetic resin between the layers is partially fused, and the fusion area and the fusion range are determined by the shape of the prepreg cut product and the shape of the preform product. Usually less than 5 percent of the surface area is sufficient.

As such a fusion method, a method capable of heating a small area can be preferably adopted, but use of an ultrasonic welder is particularly selected from the viewpoint of working efficiency.

As the fusing conditions, conditions such as a time above the softening temperature of the thermoplastic resin and below the curing temperature of the thermosetting resin or a range in which the curing does not proceed are selected. It is enough if they are fused.

The laminated product assembled in this manner is a preform product in which the phase of each layer is accurately fixed.

 Next, the present invention will be described more specifically with reference to examples.

(Example) Example 1 Use of 1200 denier nylon 6 fiber, woven density: 19 × 19 /
in, mass: 226 g / m ² plain weave, impregnated with polyvinyl butyral / phenol resin (mixing ratio 50/50 “LJ-530” manufactured by Road Far East Co., Ltd.) so as to have an adhesion amount of 56 g / m ² (No. Fig. 1) is cut into six multi-valve shapes with a diameter of 50cm.
A marking line was marked at the center of each valve, and a fusion point was marked on the marking line inside 20 mm from the end of the valve, on a circumference having a radius of 120 mm from the center, and at the center of the multi-valve valve (No. 2). 24 prepregs were prepared.

The first prepreg (dotted line) was placed in a hemispherical shape in a hemispherical assembly container having a diameter of 30 cm, and the second prepreg (solid line) was placed with a phase shift of 15 ° with respect to the first.
Using a hand-type ultrasonic welder, irradiate the fusion point of the prepreg to the extent that the two layers fuse lightly,
A circular surface having a diameter of 10 mm was fused (FIG. 3). The next sheet was laminated on the fused laminate and fused in the same manner. This operation was repeated to assemble 24 prepregs to obtain a hemispherical preform. In this preform product, the phase of each layer was accurately fixed, and the phase was not disturbed by a small external force.

This preform product was transferred to a hemispherical mold having a diameter of 25 cm, and was molded at 160 ° C./100 ton for 30 minutes to obtain a hemispherical molded product.

Through holes were drilled at 12 locations on the circumference of the molded product 80 mm above the lower edge of the periphery. Next, 20 layers were mechanically peeled one by one from the inside, and the actual number of layers at the position of the through hole was counted.

 The results are shown in Table 1.

Comparative Example 1 Using the same prepreg as in Example 1, a preform product was assembled without bonding between layers. Example 1
Under the same conditions as above, a hemispherical molded product was obtained.

Through holes were drilled at 12 locations on the circumference of the molded product 80 mm above the lower edge of the periphery. Next, 20 layers were mechanically peeled one by one from the inside, and the actual number of layers at the position of the through hole was counted.

 The results are shown in Tables 1 and 2.

As is clear from the above table, in Example 1, a uniform lamination state was obtained at all locations, whereas in Comparative Example 1, the layers were misaligned and the lamination was non-uniform.

Comparative Example 2 In Example 1, a phenolic resin was not mixed as a resin to be used, but only a polyvinyl butyral resin was used. Molded.

It was found that this molded product had blisters partially, had extremely poor releasability upon release from the mold, and it was difficult to obtain a normal molded product.

(Effects of the Invention) The present invention achieves easy and stable positioning of a laminated fabric in a molded product made by laminating a plurality of prepregs, particularly in a molded product having a complicated shape such as a three-dimensional curved body. It can be applied to the molding of various laminates because it exhibits the feature that it can be formed and does not cause a phase shift during molding.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a resin-impregnated multi-valve fabric for a laminated structure according to the present invention, FIG. 2 is an example of a cut prepreg sheet on which a fusion point is marked, and FIG. This is an example. In the figure, 1: synthetic fiber fabric, 2: synthetic resin 3: prepreg sheet, 4: fusion point 5: cut prepreg sheet, 6: first sheet 7: second sheet, 8: fused part 9: preform Goods

Claims (3)

(57) [Claims] 1. A laminate comprising a fiber cloth containing a synthetic resin mixture of a thermoplastic resin and a thermosetting resin, wherein the fiber cloths are partially positioned by heat fusion. Laminated structure. 2. After laminating a plurality of fiber cloths impregnated with a synthetic resin mixture of a thermoplastic resin and a thermosetting resin, the fiber cloths are partially heated and melted to melt the thermoplastic resin. A method for manufacturing a laminated structure, comprising: 3. The method according to claim 2, wherein the heat treatment is performed by ultrasonic waves.