JP3214647B2 - Material for molding fiber-reinforced thermoplastic resin and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a material for molding a fiber-reinforced thermoplastic resin (hereinafter referred to as FRTP) and a method for producing the same. The present invention is particularly useful when applied to the molding of FRTP having a complicated shape.

[0002]

2. Description of the Related Art As a molding material of FRTP, for example, a carbon fiber reinforced thermoplastic resin (hereinafter, referred to as CFRTP), conventionally, a thermoplastic fiber yarn such as nylon fiber, polyester fiber, polypropylene fiber or the like and a carbon fiber yarn are used. Mixed fabrics are known. Such a molding material melts only the thermoplastic fiber yarn by heating at the time of molding to form a matrix such as nylon, polyester, or polypropylene. With such a molding method, since the shear deformation of the woven fabric can be used as it is, there is an advantage that the resin can be formed into the shape of the final product at the same time as the resin impregnation at the time of molding.

However, such conventional molding materials have the following problems. Tokuhei 1-35
As proposed in Japanese Patent Application Publication No. 101-101, carbon fiber yarn and thermoplastic multifilament yarn or slit yarn (hereinafter sometimes simply referred to as thermoplastic fiber yarn) are aligned to form a warp yarn and a weft yarn. Since the fiber yarn and the thermoplastic fiber yarn are completely independent of each other and are parallel to each other, the spreadability of the carbon fiber yarn is increased even if it is heated during molding to melt the thermoplastic fiber yarn and impregnate it between the carbon fiber yarns. There is a problem that even if impregnation is not performed uniformly, impregnation cannot be performed even if pressure is applied after heating and forced impregnation is performed.

[0004] In particular, regarding the spreading property of carbon fiber yarns, in the case of ordinary carbon fiber woven yarns, the cross-sections are gathered into an elliptical shape due to the interlacing of the yarns, and the yarns are twisted. However, even if it is non-twisted, it is often difficult to sufficiently impregnate the resin because the individual fibers are entangled. In particular, when the individual fibers of each woven yarn are firmly bonded with a sizing agent, the problem becomes worse, and there is a problem that high resin impregnation cannot be expected.

[0005] Under such circumstances, recently, attempts have been made to fabricate a mixed fiber (commingle yarn) obtained by uniformly mixing carbon fibers and thermoplastic fibers. By adopting such a method, the carbon fibers and the thermoplastic fibers are uniformly dispersed in the woven fabric substrate, so that high matrix resin impregnation can be obtained.

However, in this method, even if the carbon fibers and the thermoplastic fibers are once dispersed uniformly by air entanglement or the like, the carbon fibers having extremely low elongation bear the tension due to the tension in the actual weaving process. That is, it can be easily untangled because it is stretched straight. Then, each of them becomes independent, that is, the same state as so-called alignment. In addition, there is a problem that the fiber must be mixed in advance and the production cost is high.

Further, another problem in the prior art for aligning the thermoplastic fiber yarn and the carbon fiber yarn is that a carbon fiber fabric as a base is required to obtain a fiber reinforced resin having a high handleability and a high carbon fiber content. In addition, a woven structure in which the yarn spacing is small and the eyes are closed is adopted. Then, there is a problem that the shear deformation ability of the woven fabric naturally has a limit and cannot be formed on a large curved surface.

[0008] In order to increase the shearing deformability, there are measures such as increasing the weft yarn interval or adopting a satin weave structure in which the number of intersection points in the weave structure is reduced. However, in the former, the resin is unevenly distributed in the gap between the yarns because of the open fabric, and not only becomes a fiber reinforced resin having a low carbon fiber content, but also when a stress acts on the fiber reinforced resin, Cracks are generated from weak spots unevenly distributed, resulting in a material having low strength. Further, in the latter, there is also a problem that the way of lifting the yarn on the front and back of the fabric is different, and the cured plate warps due to the curing shrinkage of the resin.

[0009]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the conventional molding materials using thermoplastic fiber yarns and slit yarns, and to solve the above-mentioned problems with the FRTP having a complicated curved surface.
However, it is an object of the present invention to provide a molding material which can be easily molded, and which is capable of molding FRTP having excellent mechanical properties, and a method for producing the same.

[0010]

In order to achieve the above object, a material for molding a fiber-reinforced thermoplastic resin according to the present invention has a flat shape.
Warp multi-filament yarn of the fabric of Do reinforcing fibers Hoyo
Interlaced as weft yarn, with less warp and weft
Both flat surfaces of at least one reinforced multifilament yarn
At least one side is made of fiber-reinforced thermoplastic by thermoforming
A thermoplastic multifilament yarn serving as a resin matrix or slit yarn made of thermoplastic resin is laminated.
Volume of the reinforcing fiber multifilament yarn.
The rate is 30 to 70% .

The woven structure of the woven fabric is usually a flat structure, but may be a twill structure or a satin structure, a triaxial woven fabric,
A bias fabric may be used in which the warp and the weft are arranged obliquely to the length direction of the fabric.

In this woven fabric, the cover factor occupied by the reinforcing fibers is preferably at least 90%, more preferably at least 95%. With such a high cover factor, the reinforcing fibers are uniformly distributed over the whole when molded into FRTP, and the generation of a resin-rich portion is suppressed, so that the FRT having uniform and high physical properties is obtained.
P is obtained.

Further, such a high cover factor can be easily attained by forming the woven yarn into a laminated structure with the above-mentioned thermoplastic multifilament yarn or slit yarn. This is more easily achieved by using a filament yarn.

[0014] Incidentally, the above cover factor Cf, an element related to the size of the gap portion formed between weaving yarns, when setting a region of area S ₁ on the textile, yarn within an area S ₁ Assuming that the area of the void formed in the above is S ₂ , it means a value defined by the following equation. Cover factor Cf = [(S ₁ −S ₂ ) / S ₁ ] × 1
The value obtained for the reinforcing fibers is the cover factor occupied by the reinforcing fibers.

The type of the reinforcing fiber is not particularly limited, and besides carbon fiber, glass fiber, polyamide fiber, polyaramid fiber, polyimide fiber and the like can be used.

In the present invention, the volume content of the reinforcing fibers is 3
The range is 0 to 70%. When the reinforcing fibers are carbon fibers, the preferred volume content is 45 to 70%. The greatest characteristics of carbon fibers are high specific strength and elastic modulus, and in order to maximize their characteristics, it is essential to increase the content of carbon fibers as much as possible. However, if an excessively high content is desired, portions (voids) where no resin is present are generated, and the strength and elastic modulus are rather reduced. As such, in the overall material of the present invention,
It is preferable that the carbon fiber has a volume content of 45 to 70%. A more preferred range is 50 to 60%.

In the material for molding a fiber-reinforced thermoplastic resin of the present invention, a laminate of a multifilament yarn of a reinforcing fiber and a thermoplastic multifilament yarn or slit yarn is used as a woven yarn of a woven fabric. It is preferable to use the woven yarn having this laminated structure for both the warp yarn and the weft yarn, but only one of them may be used.

The thermoplastic multifilament yarn or slit yarn is made of nylon, polyester, polypropylene, or polyetheretherketone (P
EEK) or a multifilament yarn or slit yarn. Regarding the thickness of the fiber yarn or slit yarn to be used, one thick fiber yarn or slit yarn may be laminated for one reinforcing fiber multifilament yarn, or a plurality of thin yarns or slit yarns may be laminated. Is also good.

Various modes of lamination can be adopted as follows. A thermoplastic multifilament yarn or slit yarn laminated on one side of the reinforcing fiber multifilament yarn, or a thermoplastic multifilament yarn or slit yarn laminated on both surfaces of the reinforcing fiber multifilament yarn. Any of these may be used. The thermoplastic multifilament yarn or the slit yarn may have a reinforcing fiber multifilament yarn laminated on both surfaces.

These laminating modes will be exemplified with reference to the drawings. FIG. 1 shows one embodiment of the fiber-reinforced thermoplastic resin molding material of the present invention, wherein 1 is a warp yarn, and a thermoplastic multifilament yarn 3 is laminated on a flat reinforcing fiber multifilament yarn 2. Is what it is. A weft yarn 4 has a thermoplastic multifilament yarn 3 laminated on a reinforcing fiber multifilament yarn 2 like the warp yarn 1. In this case, the thermoplastic multifilament yarn 3 may be laminated below the flat reinforcing fiber 2 or may be laminated on both sides. Further, it may be laminated on either the warp or the weft. Further, a plurality of (for example, two) thin thermoplastic multifilament yarns may be laminated on one reinforcing fiber yarn 2.

FIG. 2 shows an embodiment in which slit yarns of a thermoplastic resin film are laminated. Reference numeral 5 denotes a slit yarn of a thermoplastic resin film which is cut into small pieces.
The two slit yarns 5 are aligned and laminated on a flat reinforcing fiber multifilament yarn 2. In this case, the slit yarn 5 of the thermoplastic resin film to be laminated is used.
May be one, but by aligning a plurality of narrow slit yarns 5, a large amount of shear deformation at room temperature can be obtained.

That is, in the case of a slit yarn made of a thermoplastic resin , the slit width may be the same as that of a flat carbon fiber yarn, but the shear deformation ability, which is a feature of the present invention, is restricted by the slit yarn. Therefore, it is more preferable that a plurality of thin slit yarns are aligned on a flat surface of a flat carbon fiber yarn .

As is apparent from the specific embodiments shown in FIGS. 1 and 2, the fabric constituting the material for molding a fiber-reinforced thermoplastic resin of the present invention is disclosed in Japanese Patent Publication No. 1-301101. The structure is clearly different from the one in which reinforcing fiber yarns and thermoplastic fiber yarns or slit yarns are arranged side by side in parallel without being laminated , and each woven yarn is made of a reinforcing fiber multifilament yarn and a thermoplastic yarn. It is configured as a laminate of the multifilament yarns or slit yarns.

Therefore, looking at the reinforcing fiber yarn,
The texture becomes a tightly woven texture, and FRTP
Even when molded, the resin-rich portion and the generation of voids are suppressed, and a uniform and high-strength material in which the reinforcing fibers are uniformly distributed throughout can be obtained.

In the material for molding a fiber-reinforced thermoplastic resin of the present invention, in addition to the advantages associated with the above-mentioned lamination structure, it is desirable that the resin can easily conform to the mold during molding, the resin impregnation property, the cover factor of the reinforcing fiber, etc. It is. In order to satisfy such demands, the following are particularly preferable as the reinforcing fiber multifilament yarn.

That is, the convergence is a hook drop value of 1
A flat and substantially twist-free reinforcing fiber multifilament yarn in the range of 00 to 1,000 mm is used.

Here, the hook drop value is a factor relating to the convergence of the reinforcing fiber multifilament yarn, and is a value of the free fall distance of the hook measured by the following measuring method. The hook drop value is a characteristic of the reinforced multifilament yarn in the form of a woven fabric,
The measurement is performed by taking out the reinforcing fiber multifilament yarn from the woven fabric so as not to be twisted.

First, a flat reinforcing fiber multifilament yarn having a length of 120 cm was vertically loaded so that both ends of the yarn were not twisted and the flat state was not crushed under an initial load of 50 mg / denier. Fix in the direction. Next, at a position 10 cm from the upper fixing portion of the fixed reinforcing fiber multifilament yarn, a hook having a metal wire diameter of 1.0 mm and a radius of 5 mm is provided at substantially the center of the width of the reinforcing fiber multifilament yarn. Attach the weight with a 3 cm cotton thread, measure the free fall distance of the hook, and in the case of a thread, randomly extract 10 bobbins from the bobbin to be used, measure 10 times per bobbin, and measure 10 times. The average value of n = 70 obtained by removing three large values from the measured values is set as a hook drop value. In the case of a woven fabric, three 1.3-m long woven fabrics are extracted in the length direction, and the warp or weft yarns from each woven fabric are loosened so that fluff does not occur and twisting does not occur. 10 measurements of warp or weft for the woven fabric
N = 2 which is the value obtained by deleting three large values from zero measurement values
The average value of 1 is defined as the warp or weft hook drop value. In addition, the weight of the wire and the cotton yarn is made as small as possible, and the total weight of the wire, the cotton yarn and the weight is 30 g.

The larger the hook drop value is, the easier it is to open and widen the reinforcing fiber multifilament yarn. However, if the size is too large, the shape retention of the multifilament yarn is lost, and it becomes difficult to weave a woven fabric. By setting the convergence in the above range with the hook drop value, an optimum flat state of the woven yarn in the form of a woven fabric is obtained and the flat state is maintained.

For example, in the case of a woven fabric using carbon fiber yarns, air is generally blown onto the fiber bundle of the precursor in the manufacturing process of the carbon fiber in order to prevent a process trouble due to winding of the cut filament around a roller in the manufacturing process.
The filaments are entangled with each other to give the carbon fiber yarn a bundle. In addition, the sizing agent is attached to the carbon fiber yarns by the amount of the sizing agent and the adhesion between the carbon fiber filaments. The degree of convergence is determined by the degree of entanglement between filaments, the amount of sizing agent attached, and the degree of adhesion by the sizing agent. However, if the hook drop value is 100 mm or less, and the degree of convergence is too large, the convergence of carbon fiber When hand lay-up molding or prepreg processing is performed, the width of the warp and weft yarns of the woven fabric does not increase, and voids of the resin are intensively generated in the voids formed between the carbon fiber yarns. In addition, the impregnating property of the resin during processing into a prepreg deteriorates, and high-performance FRTP cannot be obtained. On the other hand, if the hook drop value is 1,000 mm or more, the convergence of the carbon fiber yarn is deteriorated, fuzzing occurs during weaving, and not only the working environment is deteriorated, but also the strength of FRTP is reduced.

It is preferable that the woven yarn composed of the above-mentioned reinforcing fiber multifilament yarn has substantially no twist. Here, "substantially no twist" refers to a state in which there is no twist of one or more turns per 1 m of yarn length. That is, it is a state in which there is no twist.

If the woven yarn is twisted, in the twisted portion, there are fibers crossing in the yarn width direction in the woven yarn and the fibers are firmly aggregated, so that the resin impregnating property is reduced. Further, the yarn width becomes narrower and converges at the twisted portion to increase the thickness, and irregularities are generated on the surface of the woven fabric. For this reason, when the woven fabric is subjected to an external force, stress concentrates on the twisted portion, and when formed into FRTP or the like, the strength characteristics become non-uniform.

With such a flat yarn, a thin woven fabric having a large yarn spacing can be obtained. Therefore, since the binding force at the crossing portion between the warp and the weft is low, it can be easily sheared. Also, since the amount of shear deformation is determined by the yarn spacing and yarn thickness, the yarn spacing is large,
In addition, since it is a flat yarn, it can be deformed until the cross section of the woven yarn becomes, for example, circular, so that the amount of shear deformation is much larger than that of a normal woven fabric. As a result, the fabric can be formed along a curved surface having a high curvature, and can be easily formed along a complicated shape. As the optimal value of the amount of shear deformation, it is desirable that the elongation ratio in the bias direction is 25% or more.

Further, since the flat yarn and the thermoplastic fiber yarn or the slit yarn are laminated to form a thin woven fabric, when the woven fabric is heated to melt the thermoplastic resin, the reinforcing fibers naturally naturally impregnate. In addition, unlike the conventional method, there is no occurrence of a portion in which the resin is unevenly distributed, and a high performance FR is obtained.
TP is obtained.

Even when the woven fabric substrate is made of a flat woven yarn, if the sizing agent is firmly attached to the woven yarn or the entanglement of the reinforcing fibers is strong, the impregnating property of the resin is reduced. There is a risk of inhibition. However, by setting the hook drop value to 100 mm or more, the reinforcing fiber yarn is spread and widened in a woven state, and the impregnating property of the resin can be kept extremely good.

It is preferable that the flat reinforcing fiber multifilament yarn as described above has a yarn thickness of 0.07 to 0.2 mm and a yarn width / yarn thickness ratio of 30 or more. If the yarn thickness is less than the above range, it is too thin to maintain the shape of the flat yarn, and if it exceeds the above range, it becomes difficult to suppress the crimp to a small value. Further, when the yarn width / yarn thickness ratio is less than 30, it is difficult to simultaneously achieve both the maintenance of the flat yarn form and the suppression of the crimp, and the achievement of the above-described hook drop value. Although the upper limit of the yarn width / yarn thickness ratio is not particularly limited, the upper limit is about 150 in consideration of the hook drop value and the easiness of the actual weaving process. In addition, the yarn width is preferably in the range of about 4 to 16 mm for easy weaving.

The woven fabric according to the present invention can have various woven structures as described above. For example, the woven yarn including the above-mentioned flat reinforcing fiber multifilament yarn is a plain woven fabric having a warp yarn and a weft yarn. In this case, the fabric thickness is 0.15 to 0.6 mm, and the fabric weight is 150 to 400 g /
m ² is preferred.

In the above woven fabric, when the reinforcing fiber multifilament yarn is a carbon fiber yarn, the carbon fiber yarn has 5,000 to 24,000 carbon fibers and a fineness of 3,
It is preferably from 000 to 20,000 denier.

Further, in the case of the above-mentioned woven fabric form, and when the flat reinforcing fiber multifilament yarn is made of carbon fiber yarn, the woven fabric weight and the fineness of the carbon fiber yarn viewed from the carbon fiber yarn are expressed by the following formula. Preferably, the relationship is satisfied, and the cover factor occupied by the carbon fiber yarn is 95% or more. W = k · D ^1/2 where, W: fabric basis weight (g / m ²⁾ k: proportional constant (1.6 to 3.5) D: fineness of the carbon fiber yarns (deniers)

By using a woven fabric having such a high cover factor, a carbon fiber reinforced resin material having a high carbon fiber filling density can be obtained, and when the carbon fiber reinforced resin material is used, there are unevenly distributed portions of the resin. Without dispersing the carbon fiber evenly, it becomes a material of high strength and elastic modulus,
High specific strength and specific elastic modulus, which are the most characteristic features of carbon fiber materials, are sufficiently exhibited.

As a method for producing the flat yarn as described above, for example, in the manufacturing process of the reinforcing fiber yarn,
A fiber bundle composed of a plurality of reinforcing fibers may be spread to a predetermined width by a roll or the like, and may be held in a flat shape or may be held in a sizing agent or the like so as not to return to the original shape. In particular, to maintain the flat shape well,
It is preferable that a small amount of about 0.5 to 2.0% by weight of a sizing agent is adhered to the flat yarn.

As described above, when the reinforcing fiber multifilament yarn is a carbon fiber yarn, a carbon fiber yarn having no twist and a fineness of 3,000 to 20,000 denier is preferred, but the fineness of the yarn is final. It may be determined according to the thickness and cost of the molded product. Particularly, a carbon fiber yarn having a small fineness and a low production cost is preferable.

At this time, the carbon fiber constituting the woven yarn has a diameter of 5 to 10 μm and is JIS-R7601.
The tensile elongation at break is 1.5 to 2.3%, the tensile strength at break is 200 to 800 kg · f / mm ² , and the tensile modulus is 2
It is preferably from 000 to 70,000 kg · f / mm ² . By using such a carbon fiber, CFRTP having high mechanical properties can be obtained.

The material for molding a fiber-reinforced thermoplastic resin comprising a woven fabric as described above is produced as follows. That is,
The method for producing a fiber-reinforced thermoplastic resin molding material according to the present invention comprises a flat reinforcing fiber multifilament yarn and a thermoplastic multifilament yarn or a thermoplastic resin.
And the laminated body is used as at least one of a warp yarn and a weft yarn.
A method of weaving the woven fabric so that the volume content of the lament yarn is 30 to 70% .

For example, as shown in FIG. 3, using a conventional rapier loom, a flat (horizontally long) heald 1 is unwound by unraveling untwisted flat reinforcing fiber yarn 10 so as to prevent untwisting.
1 mail 11a. At the same time, the reinforcing fiber yarn 1
Yarn 12 made of thermoplastic fiber so as to overlap above
And the laminated yarns are used as warp yarns 13.

At this time, it is preferable to make a difference between the supply angles of the reinforcing fiber yarn 10 and the thermoplastic resin yarn 12. It is more preferable that the heald mail 11a is vertically separated as shown in FIG. 4 because the flat state of the reinforcing fiber yarn 10 is reliably maintained. Also, it is preferable to supply the thermoplastic fiber yarn 12 in a flat shape as much as possible because it is easy to uniformly impregnate the material when the material is melted by heat. It doesn't hinder much because it flows above.

Next, in a weft yarn 16 composed of a laminate of a flat reinforcing fiber yarn 14 and a thermoplastic fiber yarn 15,
A nip-type supply device (not shown) for picking up the weft yarn while rotating the weft bobbin, and a pooling device (not shown) for storing the weft yarn during intermittent supply of the weft yarn do not cause untwisting of the weft yarn. In this way, the rapier 18 feeds the warp yarns 13 which are passed through the reed 17 and opened and closed so that the flat shape is not twisted. The thermoplastic fiber yarn 15 is preferably supplied in the same manner as the warp yarn. However, the thermoplastic fiber yarn 15 has a vertical relationship with the reinforcing fiber yarn 14 without using the nip-type supply device or the pooling device for storing the weft yarn. Two guides may be provided and supplied.

The FRTP according to the present invention is molded by using the fiber-reinforced thermoplastic resin molding material made of a woven fabric as described above. In the FRTP according to the present invention, since the thermoplastic fiber yarn or the slit yarn is laminated on the reinforcing fiber yarn, the thermoplastic fiber yarn or the slit yarn is melted and impregnated into the reinforcing fiber by directly pressing under heating. Then, the FRTP is formed.

Since the woven yarn has a laminated structure of the reinforcing fiber yarn and the thermoplastic fiber yarn or the slit yarn, the pitch between the reinforcing fiber yarns can be substantially equal to the yarn width of the reinforcing fiber yarn. Molding can be performed while maintaining a high reinforcing fiber yarn cover factor with a tight gap between them. Therefore, even in a molded state, the reinforcing fibers are uniformly distributed throughout, and the generation of resin-rich portions and voids is suppressed, and uniform and high-strength FRTP can be obtained.

Further, by using the flat and substantially twistless reinforcing fiber multifilament yarn as described above,
A very good resin impregnating property and a good fit to a mold at the time of molding are obtained. Further, the woven fabric has a small unevenness due to the small crimp of the yarn, and the formed FRT
P also has a smooth surface.

[0051]

【Example】

Example 1 A flat carbon fiber multifilament "Treca" T700S-12K (fineness: 7,200 denier) manufactured by Toray Industries, Ltd. having a flat yarn width of 6.5 mm and a nylon multifilament "Alamine" 840- manufactured by Toray Industries, Inc. 96-700 (8
40 denier) was prepared, and woven at a weave density of 1.25 yarns / cm in a plain weave structure while supplying warp and weft yarns using a rapier loom according to the following method.

First, the carbon fiber yarn of the warp yarn was unwound in a horizontal direction, and supplied to a heald mail having a horizontally long rectangular shape while keeping the flat shape of the carbon fiber. Six nylon yarns were drawn together so that the volume ratio with the carbon fiber yarn became 50%, and supplied to the mail above the heddle from above the carbon fiber yarn. On the other hand, the weft yarn is unwound while being picked up at a constant speed by a weft supply nip roller synchronized with the rotation of the weaving machine, preventing slack from occurring in the storage device acting on the intermittent weft yarn. The flat carbon fiber yarn was supplied by rapier so as not to be twisted. As with the warp yarns, six nylon yarns were arranged in a line, passed through a normal tensor and a guide, arranged on the flat carbon fiber woven yarn, and supplied by a rapier. The carbon fiber yarn used was non-twisted, and the hook drop value at a load of 30 g was 220 mm.

The obtained woven fabric has a cover factor of 97.
% And a tightly woven fabric having almost no voids in the woven yarn, and the nylon yarn is arranged by being laminated on the flat carbon fiber yarn. This woven fabric is (0 °, 90 °) / (± 45 °)
/ (± 45 °) / (0 °, 90 °) were cross-laminated, and a 0.9 mm thick cured plate was obtained by press molding. The molding was performed at a pressing force of 30 kg / cm ² and a pressing temperature of 260 ° C.

The obtained cured plate had no voids, the carbon fibers were uniformly dispersed, and the cured plate had a smooth surface. The tensile strength of the plate was measured according to the JIS-K7073 CFRP tensile test method. The results are shown in Table 1 together with the tensile dispersibility.

Comparative Example 1 For comparison, a carbon fiber multifilament “Torayca” T700S-12K (fineness 7,200) manufactured by Toray Industries, Inc.
Denier) and Toray Industries Co., Ltd. nylon multifilament "Amilan" 840-96-700 (840 denier) are prepared, and one carbon fiber yarn and six nylon yarns are aligned using a rapier loom. It was woven by the usual weaving method described.

The woven fabric was plain weave, and the warp and weft density was 1.25 / cm, with one unit of six nylon yarns aligned with carbon fiber yarns. For the warp yarn, a yarn bundle in which carbon fiber yarns and six nylon yarns are aligned is supplied to the same heald mail, and one heald is alternately moved up and down to form an opening, and the opening is formed with carbon fiber yarn as weft yarn. 6
A bundle of nylon thread-pulled yarns was fed together and woven.

The obtained woven fabric was a mesh-like woven fabric in which carbon fiber yarns and nylon yarns, or each of them were bundled together, were open. In addition, since the carbon fiber yarn and the nylon yarn are applied with different tensions, they exist independently of each other while being parallel or twisted, especially in a portion where both or the carbon fiber yarn is twisted. It was thick.

The woven fabric was prepared in the same manner as in Example 1 (0 °, 9 °).
0 °) / (± 45 °) / (± 45 °) / (0 °, 90
°) and four sheets were cross-laminated, and a 1.2 mm thick cured plate was obtained by press molding. In the woven state, the nylon yarn serving as the matrix is mainly present between the carbon fiber yarns. , Impregnation failure was observed. For the above-described reason, the obtained cured plate had many portions where the resin was missing between the carbon fiber yarns, and many voids were also generated in the carbon fiber portion. The cured plate was JIS-K70 in the same manner as in Example 1.
The tensile strength was measured according to the tensile test method of No. 73 CFRP. The results are shown in Table 1 together with the tensile modulus.

[0059]

[Table 1]

As can be seen from Table 1, according to the woven fabric substrate of the present invention, resin impregnation was excellent and high tensile properties were obtained.

[0061]

As described above, when the material for molding a fiber-reinforced thermoplastic resin and the method for producing the same according to the present invention, the woven yarn of the woven fabric base material is not simply aligned but is reinforced with a multifilament yarn of reinforced fiber. Since it is a laminate with thermoplastic multi-filament yarn or slit yarn, it has a very high shear deformation capability when it is made to conform to the mold at the time of molding, and it can conform to a complex curved mold with a large curvature. Not only is it easy to mold, but also because of its excellent resin impregnation, it can make the properties uniform and shorten the molding time.Also, it is possible to achieve a high cover factor and a high volume content of the reinforcing fiber. This makes it possible to obtain FRTP having high and uniform mechanical properties.

[Brief description of the drawings]

FIG. 1 is a perspective view of a material for molding a fiber-reinforced thermoplastic resin according to an embodiment of the present invention.

FIG. 2 is a perspective view of a fiber-reinforced thermoplastic resin molding material according to another embodiment of the present invention.

FIG. 3 is a partial perspective view of a loom, showing an example of a method for producing a material for molding a fiber-reinforced thermoplastic resin according to the present invention.

FIG. 4 is a partially enlarged longitudinal sectional view of the device of FIG. 3;

[Explanation of symbols]

 1,13 Warp yarn 2,10,14 Flat reinforcing fiber multifilament yarn 3,12,15 Thermoplastic multifilament yarn 4,16 Weft yarn 5 Thermoplastic slit yarn 11 Heald 11a Heald mail

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-289243 (JP, A) JP-A-63-115638 (JP, A) JP-A-4-270657 (JP, A) JP-A-4- 281037 (JP, A) JP-A-6-136632 (JP, A) JP-A-7-118988 (JP, A) JP-A-7-300738 (JP, A) Japanese Utility Model Application Laid-Open No. 59-61283 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) D03D 1/00-27/18 C08J 5/24

Claims (14)

(57) [Claims] 1. A multifilament yarn of a flat reinforcing fiber.
Are interlaced as warp and weft of the fabric,
And / or weft reinforcing fiber multifilament
At least one of the two flat surfaces of the
Ri and Sri made of a thermoplastic multifilament yarn or a thermoplastic resin as a matrix of fiber-reinforced thermoplastic resin <br/> Ttoyan is laminated, the reinforcing fibers Maruchifi
The volume content of the lament yarn is 30 to 70%.
Fiber-reinforced thermoplastic resin molding material according to symptoms. 2. The fabric according to claim 1, wherein the fabric has a flat structure.
Material for molding fiber-reinforced thermoplastic resin. 3. The cover factor occupied by the reinforcing fibers is 9
The material for molding a fiber-reinforced thermoplastic resin according to claim 1, which is 0% or more. 4. A piece of said reinforcing fiber multifilament yarn.
The thermoplastic multifilament yarn or slip
The material for molding a fiber-reinforced thermoplastic resin according to any one of claims 1 to 3, wherein a yarn is laminated . Wherein both of said reinforcing fiber multifilament yarn
The fiber-reinforced thermoplastic resin molding material according to any one of claims 1 to 3 , wherein the thermoplastic multifilament yarn or slit yarn is laminated on a surface . 6. The thermoplastic multifilament yarn.
Or slit yarn on both sides
The fiber-reinforced thermoplastic resin molding material according to any one of claims 1 to 3 , wherein a material yarn is laminated. 7. One reinforced fiber multifilament yarn.
The thermoplastic multifilament yarn or yarn
A plurality of lit yarns are stacked.
7. The material for molding a fiber-reinforced thermoplastic resin according to any one of 6 . 8. The multi-filament yarn for reinforcing fibers ,
Convergence is 100-1,000mm in hook drop value
Range, flat, virtually twist-free multifilament
The material for molding a fiber-reinforced thermoplastic resin according to any one of claims 1 to 7 , which is a yarn . 9. The yarn of the reinforcing fiber multifilament yarn .
The thickness is 0.07-0 . 2mm, yarn width / thickness ratio is 30 or more
The fiber-reinforced thermoplastic resin molding material according to claim 8, which is above . 10. A woven fabric having a woven fabric thickness of 0.15 to 0.6 mm,
Object basis weight is 150 and 400 / m ^2, also claim 8
9 is a fiber-reinforced thermoplastic resin molding material. 11. The multi-filament reinforced fiber yarn
The method according to any one of claims 1 to 10, which is a carbon fiber yarn.
Fiber-reinforced thermoplastic resin molding material of the mounting. 12. The carbon fiber yarn having a carbon fiber number of 5,0.
00-24,000, fineness 3,000-20,000
The fiber-reinforced thermoplastic resin molding material according to claim 11, which has 0 denier . 13. The fabric weight per unit area as viewed from the carbon fiber yarn , and
The fineness of the carbon fiber yarn satisfies the following formula
The cover factor occupied by the fiber yarn is 95% or more.
The material for molding a fiber-reinforced thermoplastic resin according to claim 11 . W = k · D ^1/2 where, W: fabric basis weight (g / m ²⁾ k: proportional constant (1.6 to 3.5) D: fineness of the carbon fiber yarns (deniers) 14. A multifilament of flat reinforcing fibers.
Yarn and thermoplastic multifilament yarn or thermoplastic
It is laminated with slit yarn made of resin, and this laminated body is
The reinforcing fibers as at least one of a warp and a weft;
The volume content of the multifilament yarn is 30 to 70%.
Fiber reinforced heat characterized by weaving a woven fabric
A method for producing a plastic resin molding material.