JP3583205B2 - Manufacturing method of cloth-like substrate composite thermoplastic member - Google Patents

Description

【００１３】
……（１）式
が成立する。
また、溶解定数をＫ、熱可塑性樹脂の分子量をＭ、熱可塑性樹脂の種類により定まる定数をａとすれば、
【００１４】
【数２】
η＝Ｋ・Ｍ^ａ ……（２）式
が成立する。
ここで、ａの値は自由屈曲性の糸マリ分子では０．５、完全に剛直な分子では２．０、普通の高分子では０．５〜１．０で溶媒によって変わる。
【００１５】
（１）式及び（２）式において、極限粘度を求めることからＣ＝０、熱可塑性樹脂を溶解可能な溶剤であるからはじき定数Ｋ≧１とし、熱可塑性樹脂が自由屈曲性糸毬分子であればａ＝０．５、熱可塑性樹脂が棒状分子（リニア）であればａ＝２．０、熱可塑性樹脂が通常高分子（ポリマ）であればａ＝０．５〜１．０とし、これらを満足するマトリックス溶液を調製する。かかるマトリックス溶液であれば、低分子量の熱可塑性樹脂から高分子量の熱可塑性樹脂まで使用することができる。但し、熱可塑性樹脂が共重合体であれば、意匠材と構造材との区分を明確にするため、追試により検討を要する。以上より、熱可塑性樹脂として市販のポリメタクリル酸メチルを採用すれば、極限粘度η＝５０を境界としてη＜５０で液体、η＞５０で固体になることから、ηが５０より小さいマトリックス溶液を採用できることがわかる。
【００１６】
こうして、布状基材にマトリックス溶液を塗布すると、マトリックス溶液中の熱可塑性樹脂の固形分がトウやヤーンの間にバインダーとして点在される。そして、時間の経過により溶剤が予備揮発し、プリプレグを得る。
次いで、第２工程において、プリプレグを所望形状に切断し、切断済プリプレグを得る。このとき、溶剤が予備揮発されていることから布状基材は半生状態であり、所望形状とほぼ等しく切断可能で、歩留まりが向上する。また、布状基材が織布であればこの際に編み目が解けることもない。
【００１７】
なお、この第２工程前にプリプレグの裏面にバッキングシートを接着することも可能である。この場合、繊維の糸の欠落を防止することができる。
また、布状基材を複数枚使用する等により、本発明に係る布状基材複合熱可塑性プラスチック部材を構造材とする場合、第２工程において、切断済プリプレグを複数枚重ねればよい。
【００１８】
この後、第３工程において、切断済プリプレグに上記マトリックス溶液を再度塗布する。これにより、第１工程での固形分が再度塗布されたマトリックス溶液と接触し、第１工程での固形分の分子が活性化されて第３工程での固形分の分子と絡みやすくなる。このとき、硬化前の変形で三次元変形も可能である。
なお、この際のマトリックス溶液の塗布厚さでプラスチック部材の表面のマトリックスの厚みを変えることができる。例えば、薄く塗布すれば表面のマトリックスが薄くなり、布状基材の立体感がマトリックスの表面に現れる。
【００１９】
そして、時間の経過により溶剤が揮発し、第１工程の固形分の分子と第３工程での固形分の分子とが相互に絡み合った状態で硬化する。この後、最終形状に切断され得る。
こうして、布状基材複合熱可塑性プラスチック部材が得られる。このプラスチック部材では、布状基材とマトリックスとは、従来のようにプレス加工による力学的な結合ではなく、熱可塑性樹脂の分子同士の絡み合いにより化学的に結合されている。また、この際、プレス加工等の設備を必要とせず、かつ常温でこれらの作業が可能である。
【００２０】
そして、このプラスチック部材は、布状基材が立体構造をそのまま維持しており、硬化開始剤の添加を必要としないことからマトリックスの透明性や艶が損なわれずに布状基材が透き通って見え、かつ表面に艶のあるものであるため、意匠材として奥行きや高級感を表現できる。
また、このプラスチック部材は、布状基材の織布又は不織布を構成する繊維（ヤーン、トウ）が互いに干渉して傷を受けにくく、押しつぶされないため、曲げ強度等の低下の心配がない。
【００２１】
なお、第３工程において、切断済プリプレグにマトリックス溶液を再度塗布した後、表面側に透明樹脂板をラミネートすることもできる。この透明樹脂板がマトリックス溶液の熱可塑性樹脂と同種のものであれば、第３工程での固形分の分子が架橋の役割を果たし、冷却された時点で双方の分子も絡み合って一体化される。このとき、透明樹脂板を加熱すれば、三次元変形が可能である。また、透明樹脂板の厚さでプラスチック部材の表面のマトリックスの厚みを変えることができる。例えば、薄い透明樹脂板を採用すれば表面のマトリックスが薄くなり、布状基材の立体感がマトリックスの表面に現れる。この場合、布状基材が織布であれば、マトリックスが織布からなる布状基材の端部に回り込んで形成されているため、端部においても編み目がしっかりと維持されている。
【００２２】
なお、本発明に係るプラスチック部材を意匠材とするか、構造材とするかは、以下のことを考慮して決定することが可能である。
【００２３】
すなわち、意匠材と構造材とは、用途により区分され得るが、他に熱可塑性樹脂が繊維のヤーンを包含し得ない量含まれているか否かによっても区分され得る。このとき、プラスチック部材中に３〜５０重量（ｗｔ）％の熱可塑性樹脂が含まれている場合には、そのプラスチック部材は意匠材として区分され得る。また、プラスチック部材中に３０〜８０ｗｔ％の熱可塑性樹脂が含まれている場合には、そのプラスチック部材は、高い曲げ弾性強度を有し、構造材として区分され得る。
【００２４】
また、本発明に係るプラスチック部材は、一般に脆い熱硬化性樹脂に比べ、粘りのある熱可塑性樹脂を用いていることから、構造材としての大きな利点が予想される。但し、プラスチック部材全体の歪みをε_ｃ 、ヤーンの歪みをε_ｙ 、熱可塑性樹脂の歪みをε_ｍ とすれば、
ε_ｃ ＝ε_ｙ ＝ε_ｍ
であるから、繊維方向をとらえた場合、ヤーンの強度が上がる程、熱可塑性樹脂の強度も高くなければ、プラスチック部材を構造材として採用する場合の利点が小さくなる。
【００２５】
【発明の実施の形態】
以下、本発明を車両のインスツルメントパネル用の意匠材に具体化した実施形態を図面を参照しつつ説明する。
「第１工程」
まず、図１（Ａ）に示すように、カーボンファイバ製の織布を布状基材１として用意する。
【００２６】
また、熱可塑性樹脂としてのポリメタクリル酸メチル並びに揮発性溶剤としてのトルエン、メタノール、キシロール及びテトラヒドラフラン（ＴＨＦ）を用意し、揮発性溶剤８５ｗｔ％にポリメタクリル酸メチルの固形分１５ｗｔ％を溶解させ、η＝３００（ｃｐｓ）のマトリックス溶液２とする。揮発性溶剤はトルエン８０ｗｔ％とメタノール３ｗｔ％とキシロール３ｗｔ％とＴＨＦ１４ｗｔ％とからなる。
【００２７】
そして、布状基材１にスプレーガンを用いてマトリックス溶液２を塗布する。この際、布状基材１の表面にマトリックス溶液２が薄く滲ませた。これにより、図８及び図９に示すように、トウ１ａやヤーン１ｂの間にはマトリックス溶液２中のポリメタクリル酸メチルの固形分２ａがバインダーとして点在される。
この後、図１（Ｂ）に示すように、布状基材１の裏面にＰＶＣ製のバッキングシート３を弱接着剤を用いて接着する。こうしている間の時間の経過により溶剤が揮発し、プリプレグ４を得る。
「第２工程」
次いで、図２に示すように、プリプレグ４を上下型５、６の間に挟持して所望形状に切断し、切断済プリプレグ７を得る。このとき、プリプレグ４の裏面にはバッキングシート３が接着され、かつ溶剤が予備揮発されていることから布状基材１は半生状態であり、所望形状とほぼ等しく切断切断され、歩留まりが向上している。また、布状基材１はこの際に編み目が解けなかった。
「第３工程」
この後、図３に示すように、切断済プリプレグ７にスプレーガンを用いて上記マトリックス溶液２を再度塗布する。この際も布状基材１の表面にマトリックス溶液２が薄く滲ませた。これにより、図８及び図９に示すように、第１工程での固形分２ａが再度塗布されたマトリックス溶液２と接触し、第１工程での固形分２ａの分子が活性化されて第３工程での固形分２ａの分子と絡みやすくなる。
【００２８】
次いで、図４に示すように、マトリックス溶液２を再度塗布した切断済プリプレグ７を図示しない加熱真空器内の賦形台８上に載置する。賦形台８の上方には遠赤外線ランプ９により加熱されるアクリル樹脂板１０が設けられており、賦形台８の下方には図示しない真空ポンプに接続された空気抜き孔が設けられている。この際、アクリル樹脂板１０としては厚さ１ｍｍのものを採用した。そして、アクリル樹脂板１０を加熱しつつ、空気抜き孔から空気を抜き取る。
【００２９】
この間、図８及び図９に示すように、切断済プリプレグ７は、賦形台８上において硬化前の変形で三次元変形するとともに、時間の経過により溶剤が揮発し、第１工程の固形分２ａの分子と第３工程での固形分２ａの分子とが相互に絡み合った状態で硬化する。また、図５に示すように、切断済プリプレグ７の表面側にアクリル樹脂板１０がラミネートされる。このアクリル樹脂板１０は、図７に示すように、マトリックス溶液２のポリメタクリル酸メチルと同種のものであるため、第３工程での固形分２ａの分子が架橋の役割を果たし、冷却された時点で双方の分子が絡み合って一体化されている。
【００３０】
この後、図６に示すように、最終形状に切断し、車両のインスツルメントパネル用の意匠材１１を得る。この間、約１２０〜３６０秒であり、従来の水圧転写等によるものと比較して１／１００〜１／１０００の短さであった。この意匠材１１では、布状基材１とマトリックス２とは、従来のようにプレス加工による力学的な結合ではなく、ポリメタクリル酸メチル同士の絡み合いにより化学的に結合されている。また、この際、プレス加工等の設備を必要とせず、かつ常温でこれらの作業が可能である。
【００３１】
そして、この意匠材１１は、図７に示すように、布状基材１が立体構造をそのまま維持しており、硬化開始剤の添加を必要としないことからマトリックス２の透明性や艶が損なわれずに布状基材１が透き通って見え、かつ表面に艶のあるものであった。特に、第３工程においてマトリックス溶液２を薄く塗布し、かつ薄いアクリル樹脂板１０を採用しているため、表面のマトリックス２が薄くなり、布状基材１の立体感がマトリックス２の表面に現れていた。このため、車両のインスツルメントパネルにこの意匠材１１を接着したところ、マトリックス２の表面の凹凸によりあらゆる方向からの光が全反射しにくかった。このため、この意匠材１１では、内部の布状基材１の立体感が明確となり、意匠材１１として奥行きや高級感を表現できて、見る者を遠くからでも引きつけるものであった。
【００３２】
また、この意匠材１１は、図６に示すように、マトリックス２が布状基材１の端部１ａに回り込んで形成されているため、端部１ａにおいても編み目がしっかりと維持されていた。このため、この点でもこの意匠材１１は見る者を引きつけるものであるとともに、端部処理が不要で製造が容易であった。
なお、他の意匠材として例えば、テーブル台に各請求項の発明を具体化する場合には、上記第３工程においてマトリックス溶液２を厚く塗布し、かつ厚いアクリル樹脂板１０を採用すれば、表面のマトリックス２が厚くなり、表面を平滑に形成することができる。このように、他の意匠材やボデー、建材等の構造材に本発明を具体化できることは上記手段等での説明通りである。
【００３３】
【発明の効果】
以上詳述したように、本発明の製造方法によれば、布状基材複合熱可塑性プラスチック部材を安価に製造できる。また、この製造方法では、大型、大面積又は複雑な形状のものであってもかかる効果を奏することができる。
【図面の簡単な説明】
【図１】実施形態に係り、（Ａ）は布状基材にマトリックス溶液を塗布している状態の模式断面図、（Ｂ）はバッキングシートを接着したプリプレグの模式断面図である。
【図２】実施形態に係り、プリプレグを切断している状態の模式断面図である。
【図３】実施形態に係り、切断済プリプレグにマトリックス溶液を再度塗布している状態の模式断面図である。
【図４】実施形態に係り、透明樹脂板をラミネートしている状態を示す模式断面図である。
【図５】実施形態に係り、透明樹脂板をラミネートした状態を示す模式断面図である。
【図６】実施形態のプラスチック部材の模式断面図である。
【図７】実施形態のプラスチック部材に係り、表面部位の拡大模式断面図である。
【図８】実施形態のプラスチック部材に係り、図７のさらなる拡大模式断面図である。
【図９】実施形態のプラスチック部材に係り、図８のさらなる拡大模式断面図である。
【符号の説明】
１…布状基材 ２…マトリックス、マトリックス溶液
１１…意匠材（布状基材複合熱可塑性プラスチック部材）
３…バッキングシート ４…プリプレグ
７…切断済プリプレグ １ａ…端部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a fabric-like substrate composite thermoplastic member. This cloth-like base material composite thermoplastic member is suitable for use as a design material such as a panel or a structural material such as a body or a building material.
[0002]
[Prior art]
BACKGROUND ART Conventionally, a plastic member in which a pattern is printed on a surface of a thermosetting resin or a thermoplastic resin by hydraulic transfer has been known. A plastic member is also known in which a pattern is formed on a polyvinyl chloride film by painting, and this film is laminated on an acrylic plate or the like. These plastic members can be preferably used as a design material because a woven cloth made of, for example, carbon fiber can be used as the pattern.
[0003]
On the other hand, a fiber reinforced plastic member (FRP) in which fibers are composited with a thermosetting resin or a thermoplastic resin is widely used. Further, there is also known a cloth-like base material reinforced thermosetting plastic member which employs a cloth-like base material made of a woven cloth made of carbon fiber and composites this with a thermosetting resin. These plastic members are preferably used as structural materials because the strength is secured by randomly dispersed fibers or cloth-like base materials.
[0004]
[Problems to be solved by the invention]
However, none of the above-mentioned conventional plastic members is sufficient as a design material. That is, since the plastic member as the design material has a planar pattern formed by printing or the like, the design material cannot express depth or luxury. In this regard, the cloth-like base material reinforced thermosetting plastic member as a structural material seems to be able to express a deep pattern by the three-dimensional structure of the cloth-like base material when the cloth-like base material is considered as a pattern. Conventionally, the cloth-like base material is bonded to the thermosetting resin by the pressure of press working, so that the cloth-like base material cannot maintain a three-dimensional structure. In addition, this plastic member requires the addition of an initiator or a catalyst for the polymerization and curing of the thermosetting resin. Since the transparency and gloss are impaired, the cloth-like base material looks cloudy or the surface becomes dull. Further, in the above-mentioned conventional FRP, fibers and the like cannot be regarded as patterns.
[0005]
Further, the plastic member as the above-mentioned conventional structural material requires press working or injection molding at the time of manufacturing, and therefore requires large-scale equipment and increases the manufacturing cost. Further, the fibers (yarn, tow) constituting the woven or non-woven fabric may interfere with each other due to the press working of the cloth-like base material, and may be damaged or crushed.
[0006]
Furthermore, when a cloth-like base material is used, the manufacturing cost rises unless the cloth-like base material is used with a high yield, for example, by cutting the cloth-like base material substantially equal to a desired shape. In particular, a cloth-like substrate made of carbon fiber woven fabric is expensive. Further, if the cloth-like base material is a woven fabric, the stitches will be loosened when cutting into a desired shape, and the design will be impaired.
The present invention has been made in view of the above-mentioned conventional circumstances, and has as its object to inexpensively manufacture a cloth-like base composite thermoplastic member excellent as a design material or a structural material.
[0007]
[Means for Solving the Problems]
The method for producing a cloth-like substrate composite thermoplastic member according to the present invention comprises preparing a cloth-like substrate made of a woven or non-woven fabric, and a matrix solution obtained by dissolving a thermoplastic resin in a volatile solvent. A first step of applying the matrix solution to a substrate and obtaining a prepreg in which the solvent is pre-evaporated; a second step of cutting the prepreg into a desired shape to obtain a cut prepreg; A third step of applying the matrix solution again and curing by volatilization of the solvent to obtain a cloth-like substrate composite thermoplastic member .
[0009]
When producing a cloth-like substrate composite thermoplastic member by the production method according to the present invention , first, in a first step, a matrix solution is applied to the cloth-like substrate.
Here, a woven fabric or a nonwoven fabric can be adopted as the cloth-like base material. Woven fabric consists of regularly woven tows, and tows are made up of hundreds or thousands of yarns. A nonwoven fabric is one in which yarn or tow fibers are irregularly integrated. As the woven or nonwoven fabric, those made of carbon fiber, those made of aromatic polyamide fiber (aramid fiber), those made of glass fiber, those made of ceramic whisker, those made of metal whisker, and the like can be adopted.
[0010]
The matrix solution is obtained by dissolving a thermoplastic resin in a volatile solvent. As the thermoplastic resin, polyethyl methacrylate (acrylic resin), acrylonitrile-butadiene-styrene resin (ABS), polystyrene (PS), polycarbonate (PC), polyvinyl chloride (PVC), polyamide (PA), and the like can be used. When the fabric base is made of carbon fiber and the design material is manufactured, the carbon fiber has good wettability to the thermoplastic resin and easily penetrates. It is not necessary to add the surfactant, but when manufacturing a structural material or when the cloth-like substrate is glass fiber, ceramic whisker, metal whisker, or the like, an appropriate surfactant is added to the matrix solution. Here, the limit of the viscosity of the matrix solution can be determined as follows.
[0011]
That is, if the intrinsic viscosity to be obtained is η (cps), the concentration is C (g / 100 cc), the converted viscosity is η _sp (cps), and the constant is C → 0,
[0012]
(Equation 1)

[0013]
... Equation (1) holds.
Further, if the dissolution constant is K, the molecular weight of the thermoplastic resin is M, and the constant determined by the type of the thermoplastic resin is a,
[0014]
(Equation 2)
η = K · M ^a Equation (2) is established.
Here, the value of a varies depending on the solvent, which is 0.5 for a free-flexible yarn molecule, 2.0 for a completely rigid molecule, and 0.5 to 1.0 for a normal polymer.
[0015]
In the formulas (1) and (2), the intrinsic viscosity is determined to be C = 0, and since the solvent is a solvent capable of dissolving the thermoplastic resin, the repelling constant K ≧ 1 is satisfied. If there is a = 0.5, if the thermoplastic resin is a rod-shaped molecule (linear), a = 2.0; if the thermoplastic resin is usually a polymer (polymer), a = 0.5 to 1.0; A matrix solution satisfying these is prepared. With such a matrix solution, a low molecular weight thermoplastic resin to a high molecular weight thermoplastic resin can be used. However, if the thermoplastic resin is a copolymer, further examination is required to clarify the distinction between the design material and the structural material. From the above, if a commercially available polymethyl methacrylate is adopted as the thermoplastic resin, the liquid crystal becomes liquid at η <50 and solid at η> 50 with the limiting viscosity η = 50 as a boundary. You can see that it can be adopted.
[0016]
Thus, when the matrix solution is applied to the cloth-like substrate, the solid content of the thermoplastic resin in the matrix solution is scattered as a binder between tows and yarns. Then, as the time elapses, the solvent is preliminarily volatilized to obtain a prepreg.
Next, in a second step, the prepreg is cut into a desired shape to obtain a cut prepreg. At this time, since the solvent is preliminarily volatilized, the cloth-like base material is in a semi-living state, can be cut almost in the same shape as the desired shape, and the yield is improved. Further, if the cloth-like substrate is a woven cloth, the stitches will not be unraveled at this time.
[0017]
Note that a backing sheet can be bonded to the back surface of the prepreg before the second step. In this case, the loss of the fiber yarn can be prevented.
In the case where the fabric-like base composite thermoplastic member according to the present invention is used as a structural material by using a plurality of fabric-like bases, a plurality of cut prepregs may be stacked in the second step.
[0018]
Thereafter, in a third step, the matrix solution is applied again to the cut prepreg. Thereby, the solid content in the first step comes into contact with the matrix solution that has been applied again, and the molecules of the solid content in the first step are activated and easily entangled with the molecules of the solid content in the third step. At this time, three-dimensional deformation is possible by deformation before curing.
In this case, the thickness of the matrix on the surface of the plastic member can be changed by the application thickness of the matrix solution. For example, if applied thinly, the matrix on the surface becomes thin, and the three-dimensional appearance of the cloth-like substrate appears on the surface of the matrix.
[0019]
Then, the solvent volatilizes with the passage of time, and the solid content molecules in the first step and the solid content molecules in the third step harden in a state where they are entangled with each other. After this, it can be cut into the final shape.
Thus , a cloth- like substrate composite thermoplastic member is obtained. In this plastic member, the cloth-like base material and the matrix are chemically bonded by entanglement of molecules of the thermoplastic resin, not by mechanical bonding by press working as in the related art. Further, at this time, equipment such as press working is not required, and these operations can be performed at normal temperature.
[0020]
Then, this plastic member, fabric-like substrate has to maintain the three-dimensional structure, fabric-like substrate is clear since it does not require intact transparency and luster of the matrix addition of the curing initiator Since it is visible and has a glossy surface, it can express depth and luxury as a design material.
Further, in this plastic member, the fibers (yarn, tow) constituting the woven or non-woven fabric of the cloth-like substrate are less likely to be damaged due to interference with each other and are not crushed, so that there is no fear of a decrease in bending strength or the like.
[0021]
In the third step, after the matrix solution is applied again to the cut prepreg, a transparent resin plate can be laminated on the surface side. If this transparent resin plate is of the same kind as the thermoplastic resin of the matrix solution, the solid content molecules in the third step play a role of crosslinking, and when cooled, both molecules are also entangled and integrated. . At this time, if the transparent resin plate is heated, three-dimensional deformation is possible. Further, the thickness of the matrix on the surface of the plastic member can be changed by the thickness of the transparent resin plate. For example, if a thin transparent resin plate is adopted, the matrix on the surface becomes thin, and the three-dimensional appearance of the cloth-like substrate appears on the surface of the matrix. In this case, if the cloth-like base material is a woven cloth, the matrix is formed around the end of the cloth-like base material made of the woven cloth, so that the stitches are firmly maintained even at the end parts.
[0022]
Na us, the plastic member according to the present invention or a design material, whether a structural member, it is possible to determined in consideration of the following.
[0023]
That is, the design material and the structural material can be classified according to the application, but can also be classified according to whether or not the thermoplastic resin is contained in an amount that cannot include the fiber yarn. At this time, if the plastic member contains 3 to 50% by weight (wt)% of the thermoplastic resin, the plastic member can be classified as a design material. When the plastic member contains 30 to 80% by weight of the thermoplastic resin, the plastic member has high bending elastic strength and can be classified as a structural material.
[0024]
Further, since the plastic member according to the present invention generally uses a sticky thermoplastic resin as compared with a brittle thermosetting resin, a great advantage as a structural material is expected. However, if the strain of the entire plastic member is ε _c , the strain of the yarn is ε _y , and the strain of the thermoplastic resin is ε _m ,
ε _c = ε _y = ε _m
Therefore, when the fiber direction is taken into account, the advantage of adopting a plastic member as a structural material decreases as the strength of the yarn increases and the strength of the thermoplastic resin does not increase.
[0025]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment in which the present invention is embodied in a design material for an instrument panel of a vehicle will be described with reference to the drawings.
"First step"
First, as shown in FIG. 1A, a woven fabric made of carbon fiber is prepared as a cloth-like substrate 1.
[0026]
In addition, polymethyl methacrylate as a thermoplastic resin and toluene, methanol, xylol and tetrahydrafuran (THF) as volatile solvents are prepared, and a solid content of 15 wt% of polymethyl methacrylate is dissolved in 85 wt% of a volatile solvent. Then, a matrix solution 2 having η = 300 (cps) is obtained. The volatile solvent is composed of 80 wt% of toluene, 3 wt% of methanol, 3 wt% of xylol, and 14 wt% of THF.
[0027]
Then, the matrix solution 2 is applied to the cloth-like substrate 1 using a spray gun. At this time, the matrix solution 2 slightly spread on the surface of the cloth-like substrate 1. As a result, as shown in FIGS. 8 and 9, solid portions 2 a of polymethyl methacrylate in the matrix solution 2 are scattered between the tows 1 a and the yarns 1 b as binders.
Thereafter, as shown in FIG. 1 (B), a backing sheet 3 made of PVC is adhered to the back surface of the cloth-like substrate 1 using a weak adhesive. The solvent evaporates with the passage of time during this process, and the prepreg 4 is obtained.
"Second step"
Next, as shown in FIG. 2, the prepreg 4 is sandwiched between the upper and lower dies 5 and 6 and cut into a desired shape to obtain a cut prepreg 7. At this time, the backing sheet 3 is adhered to the back surface of the prepreg 4, and since the solvent is preliminarily volatilized, the cloth-like base material 1 is in a semi-living state, cut and cut almost equally to a desired shape, and the yield is improved. ing. At this time, the stitches of the cloth-like substrate 1 were not unraveled.
"Third step"
Thereafter, as shown in FIG. 3, the matrix solution 2 is applied again to the cut prepreg 7 using a spray gun. Also at this time, the matrix solution 2 slightly spread on the surface of the cloth-like substrate 1. As a result, as shown in FIGS. 8 and 9, the solids 2a in the first step come into contact with the matrix solution 2 to which the solids 2a are applied again, and the molecules of the solids 2a in the first step are activated and It becomes easy to be entangled with molecules of the solid content 2a in the process.
[0028]
Next, as shown in FIG. 4, the cut prepreg 7 to which the matrix solution 2 has been applied again is placed on a shaping table 8 in a heating vacuum device (not shown). An acrylic resin plate 10 heated by a far-infrared lamp 9 is provided above the shaping table 8, and an air vent hole connected to a vacuum pump (not shown) is provided below the shaping table 8. At this time, an acrylic resin plate 10 having a thickness of 1 mm was employed. Then, while the acrylic resin plate 10 is being heated, air is extracted from the air vent holes.
[0029]
During this time, as shown in FIGS. 8 and 9, the cut prepreg 7 is three-dimensionally deformed on the shaping table 8 by deformation before curing, and the solvent is volatilized over time, and the solid content of the first step is reduced. The molecule of 2a and the molecule of the solid content 2a in the third step are cured in a state where they are entangled with each other. Further, as shown in FIG. 5, an acrylic resin plate 10 is laminated on the surface side of the cut prepreg 7. As shown in FIG. 7, since the acrylic resin plate 10 is of the same kind as the polymethyl methacrylate of the matrix solution 2, the molecules of the solid 2a in the third step play a role of cross-linking and are cooled. At this point, both molecules are intertwined and integrated.
[0030]
Thereafter, as shown in FIG. 6, the material is cut into a final shape to obtain a design material 11 for an instrument panel of a vehicle. During this period, the time was about 120 to 360 seconds, which was 1/100 to 1/1000 shorter than that obtained by conventional hydraulic transfer or the like. In the design material 11, the cloth-like base material 1 and the matrix 2 are not mechanically bonded by press working as in the related art, but are chemically bonded by entanglement of polymethyl methacrylate. Further, at this time, equipment such as press working is not required, and these operations can be performed at normal temperature.
[0031]
As shown in FIG. 7, the design material 11 retains the three-dimensional structure of the cloth-like base material 1 and does not require the addition of a curing initiator, so that the transparency and gloss of the matrix 2 are impaired. Without this, the cloth-like substrate 1 appeared transparent and had a glossy surface. In particular, since the matrix solution 2 is thinly applied in the third step and the thin acrylic resin plate 10 is employed, the matrix 2 on the surface becomes thin, and the three-dimensional appearance of the cloth-like substrate 1 appears on the surface of the matrix 2. I was For this reason, when this design material 11 was adhered to the instrument panel of the vehicle, it was difficult for light from all directions to be totally reflected due to unevenness of the surface of the matrix 2. For this reason, in the design material 11, the three-dimensional appearance of the inner cloth-like base material 1 becomes clear, and the design material 11 can express depth and a sense of quality and attract viewers from a distance.
[0032]
Further, in the design material 11, as shown in FIG. 6, since the matrix 2 is formed so as to extend around the end 1a of the cloth-like base material 1, the stitches are also firmly maintained at the end 1a. . For this reason, the design material 11 also attracts the viewer in this respect, and the end portion processing is not required, and the manufacture is easy.
As another design material, for example, when the invention of each claim is embodied on a table, if the matrix solution 2 is thickly applied in the third step and a thick acrylic resin plate 10 is used, Matrix 2 becomes thicker, and the surface can be formed smooth. As described above, the present invention can be embodied in a structural material such as another design material, a body, and a building material.
[0033]
【The invention's effect】
As described in detail above , according to the production method of the present invention, a cloth-like substrate composite thermoplastic member can be produced at low cost. Further, according to this manufacturing method, such an effect can be exerted even in a large-sized, large-area, or complex-shaped one.
[Brief description of the drawings]
FIG. 1A is a schematic cross-sectional view of a state in which a matrix solution is applied to a cloth-like substrate, and FIG. 1B is a schematic cross-sectional view of a prepreg to which a backing sheet is adhered.
FIG. 2 is a schematic cross-sectional view of a state in which a prepreg is cut according to the embodiment.
FIG. 3 is a schematic cross-sectional view showing a state in which a matrix solution is applied again to a cut prepreg according to the embodiment.
FIG. 4 is a schematic cross-sectional view showing a state where a transparent resin plate is laminated according to the embodiment.
FIG. 5 is a schematic cross-sectional view showing a state where a transparent resin plate is laminated according to the embodiment.
FIG. 6 is a schematic sectional view of a plastic member of the embodiment.
FIG. 7 is an enlarged schematic cross-sectional view of a surface portion according to the plastic member of the embodiment.
FIG. 8 is a further enlarged schematic sectional view of FIG. 7 relating to the plastic member of the embodiment.
FIG. 9 is a further enlarged schematic sectional view of FIG. 8 relating to the plastic member of the embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Cloth base material 2 ... Matrix, matrix solution 11 ... Design material (cloth base composite thermoplastic member)
3 backing sheet 4 prepreg 7 cut prepreg 1a end

Claims (1)

A cloth-like substrate made of a woven or non-woven fabric and a matrix solution prepared by dissolving a thermoplastic resin in a volatile solvent were prepared, the matrix solution was applied to the cloth-like substrate, and the solvent was pre-evaporated. A first step of obtaining a prepreg;
A second step of cutting the prepreg into a desired shape to obtain a cut prepreg;
A third step of applying the matrix solution again to the cut prepreg and curing the solvent by volatilization of the solvent to obtain a cloth-like substrate composite thermoplastic member. A method for manufacturing a plastic member.

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