JP3289783B2 - Composite reinforcing fiber material impregnated with thermoplastic resin - Google Patents
Composite reinforcing fiber material impregnated with thermoplastic resinInfo
- Publication number
- JP3289783B2 JP3289783B2 JP10896292A JP10896292A JP3289783B2 JP 3289783 B2 JP3289783 B2 JP 3289783B2 JP 10896292 A JP10896292 A JP 10896292A JP 10896292 A JP10896292 A JP 10896292A JP 3289783 B2 JP3289783 B2 JP 3289783B2
- Authority
- JP
- Japan
- Prior art keywords
- fiber
- thermoplastic resin
- reinforcing fiber
- composite
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000002131 composite material Substances 0.000 title claims description 68
- 239000012783 reinforcing fiber Substances 0.000 title claims description 55
- 239000000463 material Substances 0.000 title claims description 42
- 229920005992 thermoplastic resin Polymers 0.000 title claims description 28
- 239000000835 fiber Substances 0.000 claims description 61
- 229920005989 resin Polymers 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 12
- 230000004927 fusion Effects 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 9
- 229920001169 thermoplastic Polymers 0.000 claims description 7
- 239000004416 thermosoftening plastic Substances 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 239000002243 precursor Substances 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 4
- 238000000034 method Methods 0.000 description 12
- 239000003365 glass fiber Substances 0.000 description 9
- 239000004753 textile Substances 0.000 description 8
- 238000005470 impregnation Methods 0.000 description 6
- 239000004744 fabric Substances 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 238000012805 post-processing Methods 0.000 description 5
- 239000002759 woven fabric Substances 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 238000009941 weaving Methods 0.000 description 4
- 229920002292 Nylon 6 Polymers 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000003733 fiber-reinforced composite Substances 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 229920006268 silicone film Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000006087 Silane Coupling Agent Substances 0.000 description 1
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000009730 filament winding Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 231100000956 nontoxicity Toxicity 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229920001643 poly(ether ketone) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000009751 slip forming Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 238000001721 transfer moulding Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Description
【０００１】[0001]
【産業上の利用分野】本発明は熱可塑性樹脂をマトリッ
クスとする繊維強化複合材料の原材料および成形体に関
するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a raw material and a molded product of a fiber-reinforced composite material having a thermoplastic resin as a matrix.
【０００２】[0002]
【従来技術】熱可塑性樹脂を補強繊維に含浸したプリプ
レグが市販されているが、これらは剛直であり、織物、
組み物あるいはシート状物を作ることは困難であり、造
形性に劣る。またこれらは、曲面へのいわゆるテープ・
レーイングが困難である。一方、熱可塑性樹脂を繊維
状、あるいは粉体にしたりして補強繊維と組合せしたフ
レキシブルな材料も開発されているが、組合せ段階で不
均一を生じやすい。このため、マトリックスを補強繊維
中に均一に含浸させ、ボイドのない成形品を確実に得る
には、含浸成形工程において時間をかけた加圧が必要と
なり、工程コストが高くなるという欠点がある。2. Description of the Related Art Prepregs in which a reinforcing fiber is impregnated with a thermoplastic resin are commercially available.
It is difficult to make a braided or sheet-like material, and the formability is poor. In addition, these are so-called tapes and
Laying is difficult. On the other hand, a flexible material in which a thermoplastic resin is combined with a reinforcing fiber in a fibrous or powder form has been developed, but non-uniformity is likely to occur at the combination stage. For this reason, in order to uniformly impregnate the matrix into the reinforcing fiber and reliably obtain a molded article without voids, it is necessary to apply time-consuming pressurization in the impregnation molding step, and there is a disadvantage that the process cost is increased.
【０００３】[0003]
【発明が解決しようとする課題】本発明は前記事情を考
慮してなされたもので、その目的は、テープ・レーイン
グや製織等のテキスタイル加工ができるようなフレキシ
ビリティを有する、繊維強化熱可塑性樹脂の原材料及び
前駆体を提供し、優れた力学特性を有する成形体の形成
を可能にすることである。SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to provide a fiber-reinforced thermoplastic resin having flexibility so that textile processing such as tape laying and weaving can be performed. And the formation of a molded article having excellent mechanical properties.
【０００４】[0004]
【課題を解決するための手段】上記目的を達成するため
の本発明の構成は、複数本の補強繊維モノフィラメント
を熱可塑性樹脂で含浸被覆せしめることによって得られ
るＥ・Ｓ・ｍ・ａ2 ≦５０の条件式を満たす複合繊維単
位を２〜１６００本束ね、該複合繊維単位を長手方向に
おいて部分的に溶融させ、隣合う複合繊維単位同志を融
着させ集束して得られる熱可塑性樹脂含浸型複合補強繊
維材料、 ただし、Ｅ：補強繊維モノフィラメントの伸張弾性率
（kgf/mm2 ） Ｓ：補強繊維モノフィラメントの断面積（mm2 ） ｍ：複合繊維単位中の補強繊維モノフィラメントの本数
（−） ２ａ：複合繊維単位の断面の短径（mm） および、前記熱可塑性樹脂含浸型複合補強繊維材料を、
二次元もしくは三次元の形態に加工して得られる繊維強
化樹脂前駆体、さらには、前記熱可塑性樹脂含浸型複合
補強繊維材料、または、前記繊維強化樹脂前駆体を熱可
塑性樹脂の融点以上に加熱および加圧することにより得
られる繊維強化熱可塑性樹脂成形体である。Configuration of the present invention for achieving the above object, according to an aspect of the, E · S · m · a 2 ≦ 50 where a plurality of reinforcing fiber monofilaments obtained by impregnating coated with a thermoplastic resin A thermoplastic resin-impregnated composite obtained by bundling 2 to 1600 conjugate fiber units satisfying the following conditional expression, partially melting the conjugate fiber unit in the longitudinal direction, and fusing and binding adjacent conjugate fiber units together. Reinforcing fiber material, where E: Elongation modulus of reinforcing fiber monofilament (kgf / mm 2 ) S: Cross-sectional area of reinforcing fiber monofilament (mm 2 ) m: Number of reinforcing fiber monofilaments in conjugate fiber unit (−) 2a: The short diameter (mm) of the cross section of the composite fiber unit, and the thermoplastic resin impregnated composite reinforcing fiber material,
A fiber-reinforced resin precursor obtained by processing into a two-dimensional or three-dimensional form, and further, the thermoplastic resin-impregnated composite reinforcing fiber material, or the fiber-reinforced resin precursor is heated to a temperature equal to or higher than the melting point of the thermoplastic resin. And a fiber-reinforced thermoplastic resin molded article obtained by pressing.
【０００５】以下本発明を図面に基づいて詳細に説明す
るが、下記図面は本発明を限定するものではなく、前・
後記の趣旨に徴して変更することは本発明の技術的範囲
に含まれるものである。Hereinafter, the present invention will be described in detail with reference to the drawings, but the following drawings do not limit the present invention.
Modifications in the spirit of the following are included in the technical scope of the present invention.
【０００６】本発明に用いられる補強繊維としては、ガ
ラス繊維、炭素繊維、アラミド繊維、セラミックス繊
維、金属繊維等の連続繊維などが挙げられ、これらを、
２種以上併用して用いてもよく、また、用いる熱可塑性
樹脂との接着を良くするための表面処理がなされている
ことが好ましい。また、本発明に用いられる熱可塑性樹
脂としては、ポリエチレン、ポリプロピレン、およびそ
の共重合体や変性体を含むポリオレフィン系、ナイロン
６、ナイロン６６、ナイロン１２等のポリアミド系、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
ト等のポリエステル系、ポリカーボネート、熱可塑性ポ
リウレタン、ポリエーテルイミド、ポリフェニレンサル
ファイド、ポリエーテルケトン等が挙げられる。補強繊
維および熱可塑性樹脂は特にこれらに限定されるわけで
はない。The reinforcing fibers used in the present invention include continuous fibers such as glass fibers, carbon fibers, aramid fibers, ceramic fibers, and metal fibers.
Two or more of them may be used in combination, and it is preferable that a surface treatment for improving the adhesion with the thermoplastic resin to be used is performed. Examples of the thermoplastic resin used in the present invention include polyethylene, polypropylene, and polyolefins including copolymers and modified products thereof, polyamides such as nylon 6, nylon 66, and nylon 12, polyethylene terephthalate, and polybutylene terephthalate. Polyester, polycarbonate, thermoplastic polyurethane, polyetherimide, polyphenylene sulfide, polyether ketone and the like. The reinforcing fiber and the thermoplastic resin are not particularly limited to these.
【０００７】図１（ａ）、（ｂ）には、本発明における
複合繊維単位１の代表例の断面図を模式的に示した。複
合繊維単位１はマトリックスとなる熱可塑性樹脂２中に
補強繊維モノフィラメント３が含浸被覆されたものであ
る。FIGS. 1 (a) and 1 (b) schematically show cross-sectional views of a typical example of a conjugate fiber unit 1 according to the present invention. The composite fiber unit 1 is obtained by impregnating and coating a reinforcing fiber monofilament 3 in a thermoplastic resin 2 serving as a matrix.
【０００８】Ｌ1 は複合繊維単位断面の長径であり、Ｌ
2 は複合繊維単位断面の短径である。複合繊維単位の形
状は帯状、長方形、楕円形状であることが望ましいが、
その形状はとくに限定されるものではない。L1 is the major axis of the unit section of the conjugate fiber,
2 is the minor diameter of the composite fiber unit cross section. The shape of the composite fiber unit is preferably a band, a rectangle, and an ellipse,
The shape is not particularly limited.
【０００９】本発明においては補強繊維のモノフィラメ
ントの伸張弾性率をＥ（kgf ／mm2）、断面積をＳ（mm
2 ）、複合繊維単位中のモノフィラメントの本数をｍ
（−）、複合繊維単位断面の短径（すなわちＬ2 ）を２
ａ（mm）としたときのＥ・Ｓ・ｍ・ａ2 で計算される値
が５０以下であることが必要である。Ｅ・Ｓ・ｍ・ａ2
が５０を超える場合には、生成した複合繊維単位、及び
それを２〜１６００本集束させた熱可塑性樹脂含浸型複
合補強繊維材料のフレキシビリティが損なわれ、テキス
タイル加工等が困難になる。In the present invention, the extensional modulus of the monofilament of the reinforcing fiber is E (kgf / mm 2 ), and the cross-sectional area is S (mm).
2 ) The number of monofilaments in the composite fiber unit is m
(-), The minor axis (that is, L2) of the unit section of the composite fiber
It is necessary that the value calculated by E · S · m · a 2 when a (mm) is 50 or less. E ・ S ・ m ・ a 2
Exceeds 50, the flexibility of the formed composite fiber unit and the thermoplastic resin-impregnated composite reinforcing fiber material obtained by bundling 2 to 1600 of the composite fiber units is impaired, and textile processing or the like becomes difficult.
【００１０】各複合繊維単位中の補強繊維モノフィラメ
ントの体積含有率は、２０〜８０vol%が好ましい。補強
繊維モノフィラメントが２０vol% 以下の場合には補強
効果が有効に発揮できず、また、８０vol% 以上になる
と含浸被覆の際にボイドが発生しやすくなる。The volume content of the reinforcing fiber monofilament in each conjugate fiber unit is preferably 20 to 80 vol%. When the reinforcing fiber monofilament is 20 vol% or less, the reinforcing effect cannot be effectively exerted, and when it is 80 vol% or more, voids are easily generated at the time of impregnation coating.
【００１１】複合繊維単位の製造方法、すなわち複数の
補強繊維モノフィラメントを熱可塑性樹脂で含浸被覆す
る方法は特に規定されないが、例えば、図２に示すよう
にクロスヘッドダイを用いる方法が挙げられる。このよ
うな含浸ダイの後に更に含浸を向上させるために加圧ロ
ールを用いてもよい。A method for producing a conjugate fiber unit, that is, a method for impregnating and coating a plurality of reinforcing fiber monofilaments with a thermoplastic resin is not particularly limited, and for example, a method using a crosshead die as shown in FIG. After such an impregnation die, a pressure roll may be used to further improve the impregnation.
【００１２】また、本発明における樹脂含浸型複合補強
繊維材料は、複数本の複合繊維単位からなっているが、
該複合繊維単位の本数は２〜１６００でなければならな
い。複合繊維単位が１本の場合は、樹脂含浸型複合補強
繊維材料の可撓性が劣る傾向が大きくなる。一方、１６
００本を超える場合は、樹脂含浸型複合補強繊維材料が
太くなりすぎてテキスタイル加工が困難になる。前記複
合繊維単位を構成する補強繊維モノフィラメントの本数
ｍは、前記条件式で決定されるが、通常は２〜８００
本、好ましくは２〜４００本、更に好ましくは２〜２０
０本である。また、テキスタイル加工性等の容易性とい
う点からは、長径Ｌ1は４mm以下が好ましい。The resin-impregnated composite reinforcing fiber material of the present invention comprises a plurality of composite fiber units.
The number of the composite fiber units must be 2 to 1600. When the number of the composite fiber units is one, the flexibility of the resin-impregnated composite reinforcing fiber material tends to be poor. On the other hand, 16
If it exceeds 00, the resin-impregnated composite reinforcing fiber material becomes too thick, making textile processing difficult. The number m of the reinforcing fiber monofilaments constituting the conjugate fiber unit is determined by the above-mentioned conditional expression.
Books, preferably 2 to 400, more preferably 2 to 20
There are zero. Further, from the viewpoint of easiness of textile workability and the like, the major axis L1 is preferably 4 mm or less.
【００１３】前記樹脂含浸型複合補強繊維材料は、２〜
１６００本の複合繊維単位を束ね、さらに、図３（ａ）
に示すように複合繊維単位を長手方向において、部分的
に複合繊維単位を含浸被覆している熱可塑性樹脂を溶融
させ、該隣合う複合繊維単位同志を融着し集束されてい
る。このように集束されていることにより、各々の複合
繊維単位がバラバラにならず、かつ可撓性を保持できる
ので、テキスタイル加工等の後加工が容易になると同時
に、取扱い性にも優れる。ここで、部分的とは点、線ま
たは、小さい面積で融着されていることを意味する。さ
らに図３（ｂ）に示すように融着点において、集束する
全ての複合繊維単位を融着するのではなく、数本の隣合
う複合繊維単位を融着し、別の点において、さらに数本
の隣合う複合繊維単位を融着し、樹脂含浸型複合補強繊
維材料として集束している場合も含む。また融着点の数
（点／ｍ）は集束する複合繊維単位の本数によっても異
なるが２〜２００点／ｍが好ましく、さらに好ましくは
５〜５０点／ｍである。この範囲を下回ると、集束性が
乏しくテキスタイル加工時にヘルド等に引っかかり製織
が困難となる。一方上回ると、可撓性が損なわれ、やは
りテキスタイル加工等の後加工が困難になる。[0013] The resin-impregnated composite reinforcing fiber material may be
1600 composite fiber units are bundled, and FIG.
As shown in (1), the thermoplastic resin partially impregnating and coating the composite fiber unit in the longitudinal direction of the composite fiber unit is melted, and the adjacent composite fiber units are fused and bundled. By being bundled in this way, each composite fiber unit does not fall apart, and flexibility can be maintained, so that post-processing such as textile processing becomes easy, and at the same time, handleability is excellent. Here, "partial" means that the parts are fused at a point, a line, or a small area. Further, as shown in FIG. 3 (b), at the fusion point, instead of fusing all the bundled composite fiber units, several adjacent composite fiber units are fused, and at another point, more This also includes the case where adjacent composite fiber units of a book are fused and bundled as a resin-impregnated composite reinforcing fiber material. The number of fusion points (points / m) varies depending on the number of conjugated fiber units to be bundled, but is preferably 2 to 200 points / m, and more preferably 5 to 50 points / m. If it is less than this range, convergence is poor, and it becomes caught by a heald or the like during textile processing, making it difficult to weave. On the other hand, if it exceeds, the flexibility is impaired, so that post-processing such as textile processing becomes difficult.
【００１４】部分融着の方法は、種々の方法が適用でき
特に規定されない。例えば熱可塑性樹脂の融点以上のホ
ットエアーや、トーチを複合繊維単位を束ね走行してい
るところに、部分的に吹き付けるかまたはあぶり、部分
融着する方法が挙げられる。また別の例としては、図２
（ａ）および図２（ｂ）に示すように、複合繊維単位を
束ねたものを、ローラの円周上近くに熱可塑性樹脂の融
点以上に加熱したヒーターを部分的に配した回転ローラ
上を接触させながら走行させ部分融着する方法があげら
れる。Various methods can be applied to the method of partial fusion and are not particularly limited. For example, there is a method in which hot air having a melting point of a thermoplastic resin or more, or a method in which a torch is partially blown or blown while a composite fiber unit is running while bundled, and partially fused. As another example, FIG.
As shown in FIG. 2 (a) and FIG. 2 (b), the bundle of the conjugate fiber units is placed on a rotating roller in which a heater partially heated near the melting point of the thermoplastic resin is disposed near the circumference of the roller. A method of running while contacting and performing partial fusion is exemplified.
【００１５】このようにして得られた樹脂含浸型複合補
強繊維材料は、シート化、すだれ化、織布化、編物化、
組物化、三次元織り等の後加工により、二次元もしくは
三次元の形態にし、繊維強化樹脂前駆体にすることがで
きる。これら後加工やその形態については、一切制限を
されない。The resin-impregnated composite reinforcing fiber material thus obtained is formed into a sheet, a comb, a woven fabric, a knitted fabric,
By post-processing such as braiding or three-dimensional weaving, a two-dimensional or three-dimensional form can be obtained to obtain a fiber-reinforced resin precursor. The post-processing and the form are not limited at all.
【００１６】こうして得られる樹脂含浸型複合補強繊維
材料または繊維強化樹脂前駆体を、含浸被覆した熱可塑
性樹脂が溶融する温度まで加熱し、加圧する事により繊
維強化複合材料として成形できる。成形方法としたは、
一切制限されないが、例えば加熱した樹脂含浸型複合補
強繊維材料を加圧ロール間または加圧ベルト間を通すこ
とによって、ロッド、テープが連続的に成形される。The resin-impregnated composite reinforcing fiber material or the fiber-reinforced resin precursor thus obtained can be molded as a fiber-reinforced composite material by heating to a temperature at which the impregnated and coated thermoplastic resin is melted and pressurized. The molding method was
Although not limited at all, rods and tapes are continuously formed by, for example, passing a heated resin-impregnated composite reinforcing fiber material between pressure rolls or pressure belts.
【００１７】また、前記のようにして得られた、適当な
太さのロッドやテープを、例えば１０mmピッチに切断す
れば射出成形や圧縮成形用のペレットを作製することが
できる。さらに、前記樹脂含浸型複合補強繊維材料をそ
のまま振り落とすかまたは、所定の長さに切断しつつシ
ートを形成し、該シートを加熱加圧すればいわゆる平板
状固形状のスタンパブルシートを作ることができる。ま
た、前記樹脂含浸型複合補強繊維材料から得られた織
布、編布、組物等の布状物を加熱加圧すれば、平板状の
繊維強化樹脂が得られる。さらに、本発明による樹脂含
浸型複合補強繊維材料またはそれから得られたテープ
は、これを連続的に加熱しながらマンドレルに巻き付け
つつ加圧することによって、いわゆるフィラメントワイ
ンディング成形を行うことができる。さらには、加熱し
た多数の樹脂含浸型複合補強繊維材料、テープまたは織
布を所定形状ののダイを通しつつ引き抜くことにより、
いわゆるプルトルージョン成形を行うことができる。Further, by cutting the rod or tape having an appropriate thickness obtained as described above at a pitch of, for example, 10 mm, pellets for injection molding or compression molding can be produced. Further, the resin-impregnated composite reinforcing fiber material is directly shaken off or cut into a predetermined length to form a sheet, and the sheet is heated and pressed to produce a so-called flat solid stampable sheet. Can be. When a cloth such as a woven fabric, a knitted fabric, or a braid obtained from the resin-impregnated composite reinforcing fiber material is heated and pressed, a flat fiber-reinforced resin can be obtained. Furthermore, the so-called filament winding molding can be performed by pressing the resin-impregnated composite reinforcing fiber material according to the present invention or the tape obtained therefrom while winding it around a mandrel while continuously heating it. Furthermore, by pulling out a large number of heated resin-impregnated composite reinforcing fiber materials, tapes or woven fabrics through a die having a predetermined shape,
So-called pultrusion molding can be performed.
【００１８】また、他の有力な成形法として、樹脂含浸
型複合補強繊維材料またはその切断物をそのまま型上に
配置するか、樹脂含浸型複合補強繊維材料から得られた
布状物を型上に配置し、開放型を用いて圧縮成形する方
法が挙げられる。さらには、一般的なマッチドダイプレ
スを用いる成形法も有力である。いずれの場合において
も、樹脂含浸型複合補強繊維材料およびその後加工品
は、可撓性を有するため型に沿いやすく、成形が容易で
ある。さらに、樹脂含浸型複合補強繊維材料およびその
後加工品は、それを構成する複合繊維単位において、補
強繊維が熱可塑性樹脂で含浸被覆されているので、熱可
塑性樹脂を溶融一体化することにより、品質の優れた繊
維強化熱可塑性樹脂材料が得られる。As another influential molding method, a resin-impregnated composite reinforcing fiber material or a cut product thereof is directly placed on a mold, or a cloth obtained from the resin-impregnated composite reinforcing fiber material is placed on a mold. And compression molding using an open mold. Further, a molding method using a general matched die press is also effective. In any case, the resin-impregnated composite reinforcing fiber material and the post-processed product are flexible and easily conform to the mold and are easily molded. Furthermore, the resin-impregnated composite reinforcing fiber material and the subsequently processed product have a quality in which the reinforcing fibers are impregnated and coated with the thermoplastic resin in the composite fiber unit constituting the same, so that the thermoplastic resin is melted and integrated. A fiber-reinforced thermoplastic resin material excellent in the above is obtained.
【００１９】本発明による樹脂含浸型複合補強繊維材料
およびその後加工品は、コンクリート補強用としても有
用である。これは、熱可塑性樹脂により、補強繊維が含
浸被覆されているので、例えば、補強繊維としてガラス
繊維を用いる場合でもコンクリート中のアルカリ性物質
によってガラス繊維が劣化されることが低減される。ま
た本発明の樹脂含浸型複合補強繊維材料およびその後加
工品は繊維強化熱硬化性樹脂の強化材としても有用であ
る。例えば、本発明の樹脂含浸型複合補強繊維材料また
はその後加工品を使用してマット状物を作り、いわゆる
レジントランスファー成形のプリフォームとして用いる
ことができる。この場合は、加熱加圧することによって
容易にプリフォームが加工できる。The resin-impregnated composite reinforcing fiber material according to the present invention and the post-processed product are also useful for reinforcing concrete. This is because the reinforcing fibers are impregnated and coated with the thermoplastic resin, so that, for example, even when glass fibers are used as the reinforcing fibers, the deterioration of the glass fibers due to the alkaline substance in the concrete is reduced. Further, the resin-impregnated composite reinforcing fiber material of the present invention and a processed product thereof are also useful as a reinforcing material for a fiber-reinforced thermosetting resin. For example, a mat-like material is produced using the resin-impregnated composite reinforcing fiber material of the present invention or a subsequently processed product, and can be used as a so-called resin transfer molding preform. In this case, the preform can be easily processed by heating and pressing.
【００２０】[0020]
【発明の効果】本発明は以上のように構成されており、
マトリックスとして熱可塑性樹脂を用いるため、繊維強
化熱硬化性樹脂の場合とは異なり、 キュアリング工程が不要である。 得られた成形物がより強靭である。 材料としてのシェルフライフが極めて長い。 硬化剤やマトリックス液の毒性がなく、さらにこうし
た液状物から来る汚れがない。 という長所を有する。また熱可塑性樹脂複合材料との比
較においては、含浸プリプレグのような物に対しては、
優れた可撓性を有しテキスタイル加工等の後加工が容易
であり、しかも、型に沿い易いため成形性に優れる。ま
た、熱可塑性繊維や、粉体を用いた物と比較した場合
は、予め補強繊維が含浸被覆されているため、比較的短
時間、低圧力で、均一でかつ、ボイドのない成形品が得
られる。The present invention is configured as described above.
Since a thermoplastic resin is used as the matrix, a curing step is not required unlike the case of the fiber-reinforced thermosetting resin. The resulting molding is tougher. The shelf life as a material is extremely long. There is no toxicity of hardeners and matrix liquids, and no fouling from such liquids. It has the advantage of. In addition, in comparison with thermoplastic resin composite materials, for things like impregnated prepreg,
It has excellent flexibility and is easy to perform post-processing such as textile processing, and is excellent in moldability because it easily conforms to the mold. In addition, when compared with a thermoplastic fiber or a product using a powder, since a reinforcing fiber is impregnated and coated in advance, a molded product that is uniform and void-free at a relatively short time and at a low pressure is obtained. Can be
【００２１】[0021]
【実施例】以下に本発明の実施例を示すが、本発明はこ
れらに何ら限定されるものではない。EXAMPLES Examples of the present invention will be shown below, but the present invention is not limited thereto.
【００２２】実施例１ ノズル孔数８００の白金製ノズルを用いて引き取り速度
２０００ｍ／分でＥガラス繊維を溶融紡糸した。この繊
維を、４分割し単糸径１３μｍ、２００フィラメントの
ガラス繊維を得た。得られたガラス繊維には、シランカ
ップリング剤で処理を施した。この繊維を、図２（ａ）
に示すようなクロスヘッドダイを用いてナイロン６樹脂
を含浸被覆し、複合繊維単位を得た。複合繊維単位の繊
維含有率は５５vol%であり、長径は０．３２mm、短径は
０．１５mmであり、またガラス繊維の伸張弾性率は７２
００kgf/mm2 であり、Ｅ・Ｓ・ｍ・ａ2 は１．０８であ
った。このような複合繊維単位を４本束ね、図２（ａ）
および図２（ｂ）に示すような２６０℃に加熱したヒー
ターを有した回転ローラーに接触させ、１５点／ｍで部
分融着し集束した。融着点の面積は３×０．８mmであっ
た。この集束した樹脂含浸型複合補強繊維材料を経糸＝
１８本／inch、緯糸＝１８本／inchの平織物にレピア織
機を用いて製織した。製織性は極めて良好であった。得
られた織物を半径７cmの開放型上に多孔質の離型膜、織
物、シリコーン膜材と型に沿わせ積層した。型に対する
織物の追従性は良好であった。この積層品を融点以上に
加熱後、シリコーン膜内を減圧し、大気圧で型に押し付
け成形を行った。成形時間は加熱後１０分であった。得
られた成形品はしわ等がなく大変良好であった。また、
含浸に関しても、もともと含浸した材料を用いているた
め大変良好であった。Example 1 E glass fibers were melt spun at a take-up speed of 2000 m / min using a platinum nozzle having 800 nozzle holes. This fiber was divided into four parts to obtain a glass fiber having a single yarn diameter of 13 μm and 200 filaments. The obtained glass fiber was treated with a silane coupling agent. FIG. 2 (a)
And a nylon 6 resin was impregnated and coated using a crosshead die as shown in Table 2 to obtain a composite fiber unit. The fiber content of the conjugate fiber unit is 55 vol%, the major axis is 0.32 mm, the minor axis is 0.15 mm, and the elongation modulus of the glass fiber is 72%.
It was 00 kgf / mm 2 and E · S · m · a 2 was 1.08. FIG. 2 (a) shows a bundle of four such composite fiber units.
Then, the sheet was brought into contact with a rotating roller having a heater heated to 260 ° C. as shown in FIG. The area of the fusion point was 3 × 0.8 mm. This bundled resin-impregnated composite reinforcing fiber material is used for warp =
A plain weave of 18 yarns / inch and 18 wefts / inch was woven using a rapier loom. The weavability was very good. The obtained woven fabric was laminated on an open mold having a radius of 7 cm along with a porous release film, a woven fabric, and a silicone film material. The followability of the fabric to the mold was good. After heating the laminate to a temperature equal to or higher than the melting point, the inside of the silicone film was depressurized and pressed against a mold at atmospheric pressure to perform molding. The molding time was 10 minutes after heating. The obtained molded product was very good without wrinkles or the like. Also,
The impregnation was also very good because the impregnated material was used originally.
【００２３】比較例１ 実施例１の複合繊維単位を束ねただけで、レピア織機に
供したところ、各々の複合繊維単位がばらけ、該単位で
張力が異なり、ヘルドに引っかかり製織できなかった。Comparative Example 1 When the composite fiber units of Example 1 were simply bundled and applied to a rapier weaving machine, each composite fiber unit was disintegrated, the tension was different in each unit, and the unit was caught by a heald, and weaving could not be performed.
【００２４】比較例２ 単糸径１３μｍ、１６００本フィラメントのガラス繊維
に、実施例１と同様にナイロン６を含浸被覆し、複合繊
維単位を得た。この複合繊維単位のガラス繊維含有率は
５５vol%で、長径は１．２mm、短径は０．４１mmであ
り、Ｅ・Ｓ・ｍ・ａ2 は６４であった。この複合繊維単
位１本を樹脂含浸型複合補強繊維材料として用い、レピ
ア織機に供したところ、可撓性がないため製織すること
ができなかった。Comparative Example 2 Nylon 6 was impregnated and coated on a glass fiber having a single yarn diameter of 13 μm and 1600 filaments in the same manner as in Example 1 to obtain a composite fiber unit. The glass fiber content of this composite fiber unit was 55 vol%, the major axis was 1.2 mm, the minor axis was 0.41 mm, and E · S · m · a 2 was 64. When one of the composite fiber units was used as a resin-impregnated composite reinforcing fiber material and supplied to a rapier loom, it could not be woven due to lack of flexibility.
【図１】（ａ）、（ｂ）は代表的な複合繊維単位の断面
図である。1 (a) and 1 (b) are cross-sectional views of typical composite fiber units.
【図２】（ａ）は複合繊維単位および、樹脂含浸型複合
補強繊維材料を得るための１例の工程模式図である。
（ｂ）は部分融着装置のＡーＡ断面図である。FIG. 2 (a) is a schematic diagram of an example of a process for obtaining a composite fiber unit and a resin-impregnated composite reinforcing fiber material.
(B) is an AA sectional view of the partial fusion bonding apparatus.
【図３】（ａ）、（ｂ）は、本発明の樹脂含浸型複合補
強繊維材料の部分融着の代表的な模式図である。FIGS. 3 (a) and 3 (b) are typical schematic diagrams of partial fusion of the resin-impregnated composite reinforcing fiber material of the present invention.
１ 複合繊維単位 ２ 熱可塑性樹脂 ３ 補強繊維モノフィラメント Ｌ1 複合繊維単位の長径 Ｌ2 複合繊維単位の短径 ４ 補強繊維クリール ５ 補強繊維 ６ ガイドロール ７ 開繊装置 ８ 押出機 ９ クロスヘッドダイ １０ 複合繊維単位 １１ 集束ガイド １２ 部分融着装置 １３ ヒーター １４ 引き取り機 １５ ワインダー １６ ローラー １７ 樹脂含浸型複合補強繊維材料 １８ 溝 １９ 融着点 DESCRIPTION OF SYMBOLS 1 Composite fiber unit 2 Thermoplastic resin 3 Reinforcement fiber monofilament L1 Long diameter of a composite fiber unit L2 Short diameter of a composite fiber unit 4 Reinforcement fiber creel 5 Reinforcement fiber 6 Guide roll 7 Spreading device 8 Extruder 9 Crosshead die 10 Composite fiber unit DESCRIPTION OF SYMBOLS 11 Focusing guide 12 Partial fusion | fusing apparatus 13 Heater 14 Take-off machine 15 Winder 16 Roller 17 Resin impregnation type | mold composite reinforcing fiber material 18 Groove 19 Fusion point
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B29B 11/16 B29B 15/08 ──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. 7 , DB name) B29B 11/16 B29B 15/08
Claims (3)
可塑性樹脂で含浸被覆せしめることによって得られるＥ
・Ｓ・ｍ・ａ2 ≦５０の条件式を満たす複合繊維単位を
２〜１６００本束ね、該複合繊維単位を長手方向におい
て部分的に溶融させ、隣合う複合繊維単位同志を２〜２
００点／ｍの融着点で融着させ集束して得られる熱可塑
性樹脂含浸型複合補強繊維材料。 ただし、Ｅ：補強繊維モノフィラメントの伸張弾性率
（kgf/mm2 ） Ｓ：補強繊維モノフィラメントの断面積（mm2 ） ｍ：複合繊維単位中の補強繊維モノフィラメントの本数
（−） ２ａ：複合繊維単位の断面の短径（mm）1. An E obtained by impregnating a plurality of reinforcing fiber monofilaments with a thermoplastic resin.
2 to 1600 conjugate fiber units satisfying the condition of S · m · a 2 ≦ 50 are bundled, the conjugate fiber units are partially melted in the longitudinal direction, and adjacent conjugate fiber units are 2-2 to 2
A thermoplastic resin-impregnated composite reinforcing fiber material obtained by fusing and bundling at a fusion point of 00 points / m . E: Elongation modulus of reinforcing fiber monofilament (kgf / mm 2 ) S: Cross-sectional area of reinforcing fiber monofilament (mm 2 ) m: Number of reinforcing fiber monofilaments in composite fiber unit (−) 2a: Composite fiber unit Minor diameter of cross section (mm)
合補強繊維材料を、二次元もしくは三次元の形態に加工
して得られる繊維強化樹脂前駆体。2. A fiber-reinforced resin precursor obtained by processing the thermoplastic resin-impregnated composite reinforcing fiber material according to claim 1 into a two-dimensional or three-dimensional form.
合補強繊維材料、または、請求項２記載の繊維強化樹脂
前駆体を熱可塑性樹脂の融点以上に加熱および加圧する
ことにより得られる繊維強化熱可塑性樹脂成形体。3. A fiber obtained by heating and pressing the thermoplastic resin-impregnated composite reinforcing fiber material according to claim 1 or the fiber-reinforced resin precursor according to claim 2 at a temperature equal to or higher than the melting point of the thermoplastic resin. Reinforced thermoplastic resin molding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10896292A JP3289783B2 (en) | 1992-03-31 | 1992-03-31 | Composite reinforcing fiber material impregnated with thermoplastic resin |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10896292A JP3289783B2 (en) | 1992-03-31 | 1992-03-31 | Composite reinforcing fiber material impregnated with thermoplastic resin |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH05278031A JPH05278031A (en) | 1993-10-26 |
| JP3289783B2 true JP3289783B2 (en) | 2002-06-10 |
Family
ID=14498075
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP10896292A Expired - Fee Related JP3289783B2 (en) | 1992-03-31 | 1992-03-31 | Composite reinforcing fiber material impregnated with thermoplastic resin |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3289783B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100457408C (en) * | 2006-04-12 | 2009-02-04 | 北京中铁长龙新型复合材料有限公司 | Method for preparing three dimension stereo sandwiched carrier composite plate |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4656564B2 (en) * | 2005-02-02 | 2011-03-23 | 株式会社Ｉｈｉエアロスペース | Manufacturing method of three-dimensional fiber structure |
| US20110159233A1 (en) | 2007-04-18 | 2011-06-30 | Marissen Roelof R | Method of producing a curved product comprising drawn polymer reinforcing elements and product obtained thereby |
-
1992
- 1992-03-31 JP JP10896292A patent/JP3289783B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN100457408C (en) * | 2006-04-12 | 2009-02-04 | 北京中铁长龙新型复合材料有限公司 | Method for preparing three dimension stereo sandwiched carrier composite plate |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH05278031A (en) | 1993-10-26 |
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