JP3061235B2 - Fiber reinforced thermoplastic resin stampable sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stampable sheet in which a reinforcing material is a satin fabric and a matrix material is a thermoplastic resin.

[0002]

2. Description of the Related Art Fiber-reinforced resin molded products reinforced with high-tech fibers such as carbon fibers and aramid fibers have excellent specific strength, specific rigidity and durability. It is also rapidly spreading for leisure use.

Heretofore, as the matrix resin of these fiber-reinforced resin molded products, a distinction has been made such that a thermosetting resin is used when the reinforcing material is a continuous fiber, and a thermoplastic resin is used when the reinforcing material is a short fiber.

[0004] However, thermoplastic resins have a practically infinite life and can be molded in a short time, and are recyclable.
In particular, garbage problems such as industrial waste have been attracting much attention as they have been highlighted. In recent years, thermoplastic resins have been actively studied not only for short fibers but also for applications to composite materials reinforced with continuous fibers.

As described above, in order to manufacture a fiber-reinforced thermoplastic resin molded article using a continuous fiber as a reinforcing material and a thermoplastic resin as a matrix, first, a stampable sheet is used as a fiber-reinforced thermoplastic resin sheet reinforced with continuous fibers. There is a method of manufacturing a composite molded product by preparing in advance, then cutting this into an appropriate shape to form a blank material, and finally putting the blank material in a predetermined mold and shaping it into various shapes by press molding. .

The fiber reinforced thermoplastic resin sheet is generally called a stampable sheet because it can be press-formed like a sheet metal. The method for manufacturing the stampable sheet, by alternately laminating a matrix resin and a reinforcing fabric, by heating and pressing using a hot press,
There is a method in which the thermoplastic resin is melted and impregnated and integrated into the reinforcing fabric, and this method is called a so-called film stacking method. The texture of the reinforcing fabric used in this method includes plain weave, twill weave, satin weave and the like.

Among these woven fabrics, satin weave is other woven fabrics,
For example, since the number of lattice points is smaller than that of a plain weave or the like, it has a general property that the lattice points are easily shifted or the lattice shape is easily deformed. Therefore, the thermoplastic resin stampable sheet using the satin fabric as a reinforcing material, when shaping using the same, the reinforcing material fabric well follows the complicated shape of the mold, and gives a good deep drawn shape. It has the feature of.

[0008]

The production of stampable sheets by hot pressing generally does not use a mold.
In many cases, a laminate of a thermoplastic resin as a matrix material and a woven fabric as a reinforcing material is sandwiched from above and below with a stainless steel plate, and hot pressing is performed while determining the thickness with spacers. .
When a satin fabric is used as a reinforcing material, the satin fabric has fewer lattice points compared to other fibers, for example, a plain fabric, etc., and thus, it is difficult to suppress the weaving of the weaving yarn with the resin flow. There is a point. In addition, there is a problem in that the effective size of the stampable sheet as a product is reduced due to the swimming of the yarn.

[0009] When impregnating the reinforcing fabric with a thermoplastic resin having a high melt viscosity, the molding pressure is considerably higher than in the case of the thermosetting resin system. It encourages the swimming of threads and the look of reinforcement fabrics. In addition, when the molding temperature and the molding pressure are adjusted, the offset can be reduced, but in this case, the resin impregnating property is decreased, which is not preferable.

In the production of a stampable sheet, a satin woven fabric as a reinforcing material has fewer lattice points than other woven fabrics, so that the lattice points are likely to be misaligned. There is a problem that work takes time.

The present invention has been made as a result of intensive studies in view of the above-described problems. In the production of a stampable sheet using a satin woven fabric as a reinforcing material, the displacement of lattice points of the satin reinforced material is suppressed, and It facilitates the lay-up work of the fabric reinforcing material, suppresses the deviation caused by the weaving of the weaving yarn during the melt impregnation of the satin fabric reinforcing material of the thermoplastic resin, the product effective size of the stampable sheet is large, and It is an object of the present invention to provide a stun puzzle sheet having a high blank material cutout yield.

[0012]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a reinforcing material in which both ends in the warp direction are plain woven.
, And the two sides, which are the remaining ears, are skewed or
It is tight enough to prevent unraveling of the yarn.
The fiber-reinforced thermoplastic resin stampable sheet is a satin woven fabric and the matrix material is a thermoplastic resin.

[0013]

Further, the present invention provides a fiber-reinforced thermoplastic resin stampable sheet, wherein the reinforcing material is a carbon fiber fabric.

[0015] The fiber reinforced thermoplastic resin stampable sheet according to the present invention is a fiber reinforced thermoplastic resin stampable sheet in which a satin woven fabric and a thermoplastic resin film as reinforcements are adjusted to the hot platen size of a hot press, respectively. After cutting according to sheet specifications, these materials are alternately laminated and obtained by hot press molding.

FIG. 1 shows a reinforcing material used in the fiber-reinforced thermoplastic resin stampable sheet of the present invention. This reinforcing material is mainly composed of a satin weave portion 1 having few lattice points of yarn. The satin weave portion 1 itself is excellent in drapability and deep drawability, but is liable to cause misalignment and unraveling of the yarn, but in the present invention, the plain weave portion 2 extends over the entire width of the warp direction end 4. Is provided, the displacement of the lattice points is hardly generated. In addition, the remaining two sides other than the warp direction end 4 are firmly wrapped with the ear thread 3 so as to solve the problem of misalignment and unraveling of the yarn.

Therefore, when a fiber-reinforced thermoplastic resin stampable sheet is manufactured using the above-mentioned reinforcing fabric in the present invention, displacement of the fabric lattice points is suppressed, and the lay-up workability of the reinforcing fabric is significantly improved. Can be achieved. At the same time, it is possible to suppress the eccentricity of the woven fabric generated at the time of press molding of the laminate composed of the reinforced fabric and the thermoplastic resin sheet, and to increase the product effective size of the obtained fiber reinforced thermoplastic resin stampable sheet. Can be.

The reinforcing material woven fabric according to the present invention can use carbon fiber, aramid fiber, glass fiber, silicon carbide fiber, alumina fiber or the like singly or in combination of two or more kinds. For example, two types of different yarns can be used for the warp and the weft to form a cross-woven fabric. It is also possible to switch the weft of the plain weave portion to be discarded at the time of blank material cutting out to inexpensive fiber.

The width and length of the reinforcing fabric and the length, yarn density and basis weight of the satin weave which occupy most of the reinforcing fabric are determined by the size of the hot press hot platen, the fiber reinforced thermoplastic resin to be manufactured. Can be set arbitrarily according to the specifications of the stampable seat.

On the other hand, the length of the plain weave portion varies depending on the width of the reinforcing material woven fabric, the length of the satin weave portion, the type of yarn in the plain weave portion, the yarn density and the basis weight. That is, the lay-up operation of the reinforcing material fabric becomes more difficult as the size of the reinforcing material fabric increases. In addition, the amount of resin flow during the melt impregnation of the reinforcing material woven fabric with the thermoplastic resin increases as the size of the fiber-reinforced thermoplastic resin stampable sheet increases.

Therefore, the size of the fiber reinforced thermoplastic resin stampable sheet is controlled in order to suppress the displacement of lattice points at the time of lay-up of the reinforcing material woven fabric, and to suppress the weaving of the weaving yarn during melt impregnation of the thermoplastic resin. The larger the is, the larger the plain weave must be and must be woven tightly.
However, as described above, the plain weave portion is a portion that is discarded when blank material is cut out, so that it is not preferable that the plain weave portion is too large or too dense.

A reinforcing material woven fabric for providing a fiber reinforced thermoplastic resin stampable sheet of a general size, using carbon fiber as a woven yarn, a width of 60 to 120 cm, and a length of a satin woven portion of 60 to 120 cm.
In the case of 240 cm, the plain weave portion has a yarn density of 100 to
What is necessary is just to be 1500 pieces / m, the basis weight 50-700 g / m < ² > , and length (one side) 0.5-2.0 cm.

The reinforcing material woven fabric is usually woven with a predetermined number of warps according to the width of the woven fabric, the woven yarn and the density of the woven yarn, and a lot of about 1000 m length.

The reinforced fabric according to the present invention, as described above,
The width and length of the satin weave and plain weave are determined according to the hot plate size of the hot press to be used. The width of the fabric is
It can be changed by changing the setting of the loom, and the setting of the length of the satin weave and the plain weave can be controlled almost freely with a punch card.

In the present invention, since the continuous woven reinforced fabric is cut into a predetermined size and used, the type of yarn is changed during weaving so that the woven fabric is used as a mark for cutting later, over the entire width. Stitching can also be applied. For example, it is a good mark to use white glass fiber and yellow aramid fiber for black carbon fiber. The loom usually has a plurality of shuttles, and can freely switch the type of yarn.

The thermoplastic resin used in the present invention includes, for example, polycarbonate, nylon 6, nylon 12, polyether sulfone, polyether ether ketone,
Polyetherimide, polypropylene, polyethylene,
Polyurethane. By laminating a resin film made of these resins at an arbitrary ratio with a woven fabric at the time of lay-up, a fiber-reinforced thermoplastic resin stampable sheet having a desired thickness and fiber volume mixing ratio can be obtained.

[0027]

【Example】

[Example 1] Using a PAN-based high-strength carbon fiber "Vesfight HTA 7-3K" (trade name) (trade name: 7 µ x 3000 filaments) manufactured by Toho Rayon Co., Ltd., the following Table 1
Carbon fiber woven fabric A (plain weave, 2 cm woven in the warp direction of the woven fabric, switched to 8-sheet satin weave, woven 98 cm).
After repeating this process 50 times, finally,
cm weave. ) Was prepared.

Next, each of the carbon fiber fabric A and the polycarbonate resin film (200 μm thick) was cut into a 1 m square sheet. At the time of cutting the carbon fiber fabric A, the plain weave portions were arranged at both ends of the fabric by 1 cm each. Six sheets of carbon fiber fabric A (see FIG. 1) and seven sheets of polycarbonate resin film were prepared, and the resin film and carbon fiber fabric A were alternately laminated. These lay-up workability was good.

The laminate is sandwiched between stainless steel plates which have been subjected to a release treatment in advance, set on a hot press hot plate, and about 2.7 mm thick using a steel spacer which has also been subjected to a release treatment. A fiber reinforced thermoplastic resin stampable sheet was produced. The molding condition is such that the molding pressure is P1 (kg / c
m ² ), the molding temperature is t 1 (° C.), the temperature before the start of heating is t 0 (° C.), the time when the temperature reaches the set temperature to be molded is θ 1 at the start of pressurization, and the time at the start of cooling is θ 2 In this case, the procedure was performed as shown in Table 2 and FIG.

That is, the hot press heats the object from the heating start temperature t0 (° C.) until it reaches t1 (° C.), and when the set temperature is reached, the forming pressure P1
(Kg / cm ² ). During this pressurization,
When reaching θ2, cooling is started while the pressurization is continued. The pressure is released at the time point θ3 when the cooling temperature reaches t0 (° C.). Molding temperature t1 (° C.), molding pressure P1
Specific values of (kg / cm ² ) and the holding time (θ2-θ1) from θ1 to θ2 are as shown in Table 2 below.

The evaluation of the fiber reinforced thermoplastic resin stampable sheet obtained by such a molding treatment is shown in Table 2 below. In the fiber-reinforced thermoplastic resin stampable sheet of Example 1, the portion where the misalignment occurred was about 5 mm (in a plain weave structure) from the sheet end, and the eight satin weave portions were not disturbed at all. Next, the internal void ratio was measured according to ASTM D2734, and it was confirmed that the void ratio was as low as 0.9% and the resin impregnation was excellent.

[Comparative Example 1] PAN-based high-strength carbon fiber "Vesfight W-3121" (trade name) (8 sheets satin weave) manufactured by Toho Rayon Co., Ltd. with specifications shown in Table 1 below, polycarbonate resin film ( (200 μm thick) were cut into 1 m square sheets. Six sheets of carbon fiber fabric and seven sheets of polycarbonate resin film were prepared, and the resin film sheet and the carbon fiber fabric sheet were alternately laminated. Lay-up workability was poor due to the displacement of lattice points, and required about twice as long as in the first embodiment.

The above laminate is sandwiched between stainless steel plates which have been subjected to a release treatment in advance, set on a hot press hot platen, and about 2.7 mm thick using a steel spacer which has also been subjected to a release treatment. Was manufactured. The molding conditions are as shown in Table 2 and FIG.

The evaluation of the obtained fiber reinforced thermoplastic resin stampable sheet is shown in Table 2 below. In the fiber reinforced thermoplastic resin stampable sheet of Comparative Example 1, the portion where the misalignment occurred was 20 to 25 mm from the sheet end.

[0035]

[Table 1] [Comparative Examples 2 to 5] In the same manner as in Comparative Example 1, PAN-based high-strength carbon fiber “Vesfight W” manufactured by Toho Rayon Co., Ltd.
-3121 "(trade name) (8 satin weaves) and a polycarbonate resin film (200 micron thick) were prepared, and each was cut into 1 m square.

Six carbon fiber woven sheets and seven polycarbonate resin film sheets were laminated so that the resin film sheets and the carbon fiber woven sheets were alternated. Lay-up workability was poor, and required about twice as long as in the first embodiment.

The laminate was set on a hot press hot platen in the same manner as in Comparative Example 1 and a molding temperature and pressure lower than those in Comparative Example 1 were applied to examine the suppression of misalignment. . The molding conditions are as shown in Table 2 and FIG.

The evaluation of the obtained fiber reinforced thermoplastic resin stampable sheet is shown in Table 2 below.

[0039]

[Table 2] According to the fiber reinforced thermoplastic resin stampable sheets of Comparative Examples 2 to 5, by setting the molding temperature (t1) and the molding pressure (p1) to be relatively low, it is possible to relatively suppress the resin flow and the offset. Got the prospect of becoming. However, according to the evaluation of the stampable sheets of Comparative Examples 2 to 5 shown in Table 2, the stampable sheets produced under these molding conditions all have a high void ratio and are inferior in resin impregnation. .

On the other hand, by increasing the holding time (θ2−θ1), the impregnation tends to be improved, but the effect is small and it is judged that it is not preferable from the viewpoint of productivity.

[Examples 2 to 6] A carbon fiber fabric A was prepared in the same manner as in Example 1. In addition, various resin films shown in Table 3 below were prepared, and each was cut into 1 m square. Six sheets of carbon fiber fabric A and seven sets of resin film sheets (one set corresponding to a thickness of 200 microns) were prepared. One set of the resin film sheets and one sheet of the carbon fiber fabric A were alternately laminated. Lay-up workability was good.

The laminate was molded in the same manner as in Example 1 to obtain a 2.7 mm thick fiber reinforced thermoplastic resin stampable sheet. The molding conditions are as shown in Table 3 below and FIG. The evaluation of the obtained fiber-reinforced thermoplastic resin stampable sheet is shown in Table 3 below.

[0043]

[Table 3] According to Table 3, in the fiber-reinforced thermoplastic resin stampable sheets of Examples 2 to 6, the misalignment occurrence portion was set to about 5 mm (in the plain weave structure) from the sheet end, and the eight-sheet satin weave was used. It was not disturbed at all. In addition, the first embodiment
As a result of the void ratio measurement performed in the same manner as in the above, all the void ratios showed a low value of about 1%, and it was confirmed that the resin impregnation property was good.

[0044]

According to the present invention, the reinforcing material is a satin woven fabric in which both ends in the warp direction are plain woven, and the matrix material is a fiber reinforced thermoplastic resin stampable sheet. It is possible to suppress the occurrence of lattice point shift of the satin reinforced fabric during the production of the stampable sheet. This facilitates the lay-up work of the satin reinforced material during the production of the stampable sheet, and suppresses misalignment caused by the weaving out of the yarn during the melt impregnation of the thermoplastic resin into the satin reinforced material. A stampable sheet having a large product effective size of the sheet and a high blank material cutout yield can be provided.

[Brief description of the drawings]

FIG. 1 shows a reinforcing material used for a fiber-reinforced thermoplastic resin stampable sheet of the present invention.

FIG. 2 shows molding conditions applied to Examples and Comparative Examples.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Satin weave part 2 Plain weave part 3 Ear thread 4 Warp direction end

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-27189 (JP, A) JP-A-59-100403 (JP, U) JP-A-5-69182 (JP, U) (58) Investigation Field (Int.Cl. ⁷ , DB name) B29B 11 / 16,15 / 08 C08J 5 / 04,5 / 24 D03D 1/00

Claims (2)

(57) [Claims] 1. The reinforcing material has a plain weave at both ends in the warp direction, and the other two sides as ears are offset or woven yarn of the woven fabric.
Vermilion that is strong enough to prevent unraveling
A fiber-reinforced thermoplastic resin stampable sheet, which is a child fabric and a matrix material is a thermoplastic resin. 2. The fiber reinforced thermoplastic resin stampable sheet according to claim 1, wherein the reinforcing material is a carbon fiber woven fabric.