JP6537430B2 - Reinforcement sheet and method of manufacturing the same - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a reinforcing sheet in which carbon fibers opened on the surface of a thin film sheet are arranged in parallel and integrated integrally, and a method of manufacturing the same.

  Carbon fibers are well known as reinforcing fibers such as carbon fiber reinforced resins. Carbon fiber reinforced resin using carbon fiber is widely applied to various sporting goods such as golf club shafts and fishing rods, aircraft, automobiles, pressure vessels etc. by taking advantage of features such as high strength and light weight, and future applications It is also expected. As a prior art, a reinforcing fiber sheet for reinforcement is proposed in which reinforcing fiber bundles such as carbon fibers are aligned in one direction and adhered to a sheet-like support by a nonwoven fabric containing a low melting point polymer (Patent Documents 1 and 2) .

Japanese Patent Application Laid-Open No. 11-000959 Japanese Patent Laid-Open No. 2000-19815

  However, since the reinforcing sheet of the prior art arranges the carbon fiber bundles in one direction as it is, there are problems such as difficulty in handling due to the thick reinforcing sheet and considerably increasing the original thickness of the object to be reinforced. was there. Further, for example, in the case of application in which a thermosetting resin is impregnated, there is a problem that the resin is difficult to be impregnated.

  In order to solve the above-mentioned conventional problems, the present invention provides a reinforcing sheet which is thin and easy to be impregnated with a resin, and a method of manufacturing the same.

The reinforcing sheet of the present invention is a reinforcing sheet in which a group of carbon fiber filaments is laminated on at least one surface of a thin film sheet, and the group of carbon fiber filaments is opened , and each filament is arranged in parallel in one direction. and arranged, and which distance is opened for every predetermined number, the thin film sheet is at least one of the thin film sheet selected from non-woven fabric and paper, and the thin film sheet and the parallel-shaped carbon fiber filament group The distance between the predetermined number of parallel carbon fiber filaments is 3 to 100 mm, and the relationship between the width of the opened carbon fiber filaments and the distance is as follows: It is characterized in that it is 70 to 85% in the formula of .
Ratio of width of opened carbon fiber filament group (%) = width of opened carbon fiber filament group (mm) / [width of opened carbon fiber filament group (mm) + spacing (mm) ] × 100

  The method for producing a reinforcing sheet according to the present invention is the method for producing the reinforcing sheet, wherein the carbon fiber filament group is opened, and the filaments are arranged in parallel in one direction, and arranged in parallel in the one direction. An adhesive is applied to one surface of the group of carbon fiber filaments, and a thin film sheet is stacked thereon, and the thin film sheet and the group of carbon fiber filaments are bonded and integrated.

  Another method of manufacturing a reinforcing sheet according to the present invention is a method of manufacturing the reinforcing sheet, wherein a group of carbon fiber filaments is opened and arranged so that the filaments are arranged in parallel in one direction, and arranged in parallel in the one direction. A powdery adhesive is sprinkled onto one surface of the carbon fiber filaments arranged in the above, and the thin film sheet is superposed thereon and heated to bond and integrate the thin film sheet and the carbon fiber filaments. .

  In the reinforcing sheet of the present invention, in the group of carbon fiber filaments, the filaments are arranged in parallel in one direction, the thin film sheet is at least one thin film sheet selected from non-woven fabric and paper, and the thin film sheet and Since the parallel carbon fiber filaments are integrated by adhesion, it is possible to provide a reinforcing sheet which is thin and easy to be impregnated with resin, and a method of manufacturing the same.

FIG. 1A is a schematic plan view of the surface of a reinforcing sheet according to an embodiment of the present invention, and FIG. 1B is a schematic cross-sectional view taken along line I-I of FIG. 1A. FIG. 2A is a schematic plan view of the surface of a reinforcing sheet according to another embodiment of the present invention, and FIG. 2B is a schematic rear view of the same. FIG. 3 is a schematic process diagram showing a method of manufacturing a reinforcing sheet according to an embodiment of the present invention.

  In the reinforcing sheet of the present invention, carbon fiber filaments are laminated on at least one surface of a thin film sheet. Here, "carbon fiber filament group" means that it is a large number of carbon fiber filaments. For example, 6K (6000), 12K (12000), 24K (24000), 48K (48000), 50K (50000) or the like. Preferably, they are 12 K to 50 K, and the fineness is 800 g / 1000 m to 3700 g / 1000 m. In the carbon fiber filament group, the filaments are arranged in parallel in one direction. The carbon fiber filaments are arranged on one side or both sides of the thin film sheet.

  The thin film sheet is at least one thin film sheet selected from non-woven fabric and paper. The thin film sheet is thin and has high adhesion to an adhesive. Therefore, it is easy to adhere to the carbon fiber filaments and to other materials. The thin film sheet and the parallel carbon fiber filament group are integrated by adhesion. As a result, the reinforcing sheet is thin and easy to be impregnated with the resin.

  As the non-woven fabric, spunbonded non-woven fabric, needle-punched non-woven fabric, chemically bonded non-woven fabric, thermal bonded non-woven fabric, stitch bonded non-woven fabric, meltblown non-woven fabric, spunlaced non-woven fabric, hydroentangled non-woven fabric, wet non-woven fabric, etc. can be used. As the paper, high quality paper, kraft paper, glassine paper, parchment paper, synthetic resin film laminated paper, synthetic paper and the like can be used.

The parallel carbon fiber filaments are arranged at predetermined intervals. As a result, the spaced portions can be used as a bonding area (adhesive), and the adhesion between reinforcing sheets or other materials is improved. The distance between the predetermined number of the parallel carbon fiber filament groups is preferably 3 to 100 mm, more preferably 5 to 50 mm. In addition, the relationship between the width of the opened carbon fiber filament group and the distance between the predetermined number of carbon fiber filament groups is the opened carbon fiber in view of the balance between the reinforcing performance of the reinforcing sheet and the lightness. It is preferable that the ratio of the width of the filament group is 70 to 85%. In addition, the ratio of the width | variety of the opened carbon fiber filament group is calculated | required by the following formula.
Width ratio of opened carbon fiber filament group (%) = width of opened carbon fiber filament group (mm) / (width of opened carbon fiber filament group (mm) + open for every predetermined number Distance (mm) × 100

The thickness of the reinforcing sheet is preferably 0.05 to 0.5 mm, more preferably 0.1 to 0.3 mm. Moreover, as for the thickness of the said parallel carbon fiber filament group, 0.03-0.15 mm is preferable. If it is the said thickness, it can reduce in weight and it is easy to impregnate resin. Furthermore, as for the mass per unit area of the said reinforcement sheet, 30-150 g / m < ² > is preferable. If it is the said mass, it can be set as a lightweight reinforcement sheet.

  The non-woven fabric is preferably composed of at least one fiber selected from synthetic fibers and glass fibers. These fibers can also be used as a reinforcing material. As synthetic fibers, polyolefin fibers, polyester fibers, aramid fibers, other super fibers, etc. can be used.

  On the back surface of the thin film sheet, the filaments of the carbon fiber filament group are arranged in parallel in one direction in parallel and laminated, and the carbon fiber filaments laminated on the back surface of the thin film sheet are carbon laminated on the surface Preferably, it is the same as or different from the direction of the fiber filaments. Thereby, it can be set as a reinforcement sheet which has intensity in various directions.

  In the method of manufacturing a reinforcing sheet of the present invention, first, carbon fiber filament groups are opened and arranged such that the filaments are arranged in parallel in one direction. As an example, a carbon fiber filament group is opened according to the opening method of carbon fiber (Unexamined-Japanese-Patent No. 2010-270420). When using multiple pairs of nip rolls, carbon fiber filament groups are gradually opened. Alternatively, air may be blown to the carbon fiber filaments in combination with a roll.

  Next, an adhesive is applied to one surface of the carbon fiber filaments arranged in parallel in one direction, and a thin film sheet is superposed thereon, and the thin film sheet and the carbon fiber filaments are bonded and integrated. . The adhesive is preferably an epoxy adhesive. The epoxy adhesive may be powder or liquid. Preferably, a powdery adhesive is sprinkled on one surface of the carbon fiber filaments arranged in parallel in one direction, and a thin film sheet is superposed thereon, and then heated to heat the thin film sheet and the carbon fiber filaments. Bond and integrate. The powdery adhesive is preferably an epoxy-based powder adhesive, for example, XB 3366 manufactured by HUNTSMAN, EPIKOTE 05390 manufactured by MOMENTIVE, and EPIKOTE 620. It is preferable to pressurize with a roll etc. at the time of heating.

  Next, it demonstrates using drawing. In the following drawings, the same symbols indicate the same things. FIG. 1A is a schematic plan view of the surface of a reinforcing sheet according to an embodiment of the present invention, and FIG. 1B is a schematic cross-sectional view taken along line I-I of FIG. 1A. In the reinforcing sheet 1, the filaments of the carbon fiber filament group 3 are arranged in parallel in one direction on one surface of the thin film sheet 2 and integrated by adhesion. It is preferable to place on the thin film sheet only the minimum amount of carbon fiber necessary to produce a reinforcing effect, and the carbon fiber filament groups 3 are arranged in parallel at intervals, and this interval is opened. The portion 4 can also be used as a bonding area. The carbon fiber filament groups 3 are arranged side by side substantially in a line as shown in FIG. 1B. This reinforcing sheet can be used alone or in combination of a plurality of sheets. When laminating and using a plurality of sheets, carbon fiber filaments can be used with different directionality.

FIG. 2A is a schematic plan view of the surface of a reinforcing sheet according to another embodiment of the present invention, and FIG. 2B is a schematic rear view of the same. In the reinforcing sheet 5, the filaments of the carbon fiber filament group 7 are arranged in parallel in one direction on the surface 6a of the thin film sheet and integrated by adhesion. The carbon fiber filaments 7 are arranged in parallel spaced apart, so that the spaced apart parts 8 can also be used as adhesive areas.
As shown in FIG. 1B, in the back surface 6b, the filaments of the carbon fiber filament group 9 are arranged in parallel in one direction in a direction perpendicular to the front surface and integrated by adhesion. The carbon fiber filaments 9 are arranged in parallel at intervals, whereby the spaced portions 10 can also be used as adhesive regions (sticking).

  FIG. 3 is a schematic process diagram showing a method of manufacturing a reinforcing sheet according to an embodiment of the present invention. The carbon fiber filament group 12 is drawn out from the plurality of winding bodies 11, passed through the nip rolls 19a, 19b and 19c, 19d, and the carbon fiber filament group 12 is opened to arrange the filaments in parallel in one direction. Do. The powdery adhesive 14 b is sprinkled from the powdery adhesive container 14 a onto the surface of the obtained carbon fiber filament group 13. On the other hand, the thin film sheet 16 wound around the roll 15 is drawn out, passed through the guide roll 17, superimposed on the carbon fiber filament group 13 sprinkled with the powdery adhesive 14b, passed through the heater 18, and nip rolls 19e and 19f. Under pressure, the non-woven fabric 16 and the carbon fiber filament group 13 are bonded and integrated to form a reinforcing sheet 20 and wound around the winding body 21. This reinforcing sheet can be used alone or in combination of a plurality of sheets. When laminating and using a plurality of sheets, carbon fiber filaments can be used with different directionality.

  Hereinafter, the present invention will be specifically described using examples. The present invention is not limited to the following examples.

Example 1
A carbon fiber filament group (15K) manufactured by Mitsubishi Rayon Co., Ltd. and a total fineness of 1000 g / 1000 m were used as reinforcing fibers, and this carbon fiber filament group was manufactured by the method shown in FIG. The thin film sheet used glass fiber non-woven fabric (mass 30 g / m ² ). The adhesive used was an epoxy adhesive "EPIKOTE 05390" manufactured by MOMENTIVE, and was applied at a ratio of 10 g / m ² to a carbon fiber filament group after fiber opening. Subsequently, the thin film sheet was laminated from the upper side, then heated at a heater temperature of 160 ° C., and pressure-adhered by passing between nip rollers. The line speed was 10 m / min.
The obtained reinforcing sheet is shown in FIG. The width (width after fiber opening) of the parallel carbon fiber filaments was 25 mm, and the distance between the carbon fiber filaments was 8 mm. In addition, the ratio of the width | variety of the opened carbon fiber filament group was 76%, and the mass of the obtained reinforcement sheet was 68 g / m < ² >. The thickness of each component is collectively shown in Table 1.

(Example 2)
The experiment was performed in the same manner as in Example 1 except that a polyethylene terephthalate fiber spunlace nonwoven fabric (mass: 16 g / m ² ) was used as the thin film sheet. The width (width after fiber opening) of the parallel carbon fiber filaments was 25 mm, and the distance between the carbon fiber filaments was 8 mm. The mass of the obtained reinforcing sheet was 54 g / m ² . The thickness of each component is collectively shown in Table 1.

(Example 3)
A carbon fiber filament group (50K) manufactured by SGL, a total fineness of 3300 g / 1000 m, was used as a reinforcing fiber, and this carbon fiber filament group was manufactured by the method shown in FIG.
Paper (mass 50 g / m ² ) was used as the thin film sheet. The width (width after fiber opening) of the parallel carbon fiber filaments was 50 mm, and the distance between the carbon fiber filaments was 12.5 mm. In addition, the ratio of the width | variety of the opened carbon fiber filament group was 80%, and the mass of the obtained reinforcement sheet was 111 g / m < ² >. The thickness of each component is collectively shown in Table 1.

As apparent from Table 1, it was confirmed that the thickness of each example was extremely thin. If it is so thin, it becomes a reinforcing sheet which is easily impregnated with the resin, and the thinness of the reinforcing sheet makes it easy to handle and to reinforce the object to be reinforced in a state close to the original shape.
In addition, the parallel carbon fiber filament groups are arranged at intervals by a predetermined number so as not to load carbon fibers more than necessary, so that the spaced apart portions serve as bonding areas (sticking margin). It could be used, and it was also confirmed that the adhesion between reinforcing sheets or to other materials was improved.

  The reinforcing sheet of the present invention can be widely applied to reinforcing materials of various boards (plate-like members), vehicle reinforcing materials, shafts of golf clubs, various sporting articles such as fishing rods, aircraft, automobiles, pressure vessels and the like.

1,5,20 Reinforcement sheet 2,16 Thin film sheet 3,7,9,13 Carbon fiber filament group 4,8,10 Spaced part 6a Front surface 6b of thin film sheet Back surface 11 of thin film sheet Winding body 12 Carbon fiber Filament group 14a Powdered adhesive container 14b Powdered adhesive 15, 22 Roll 17 Guide roll 18 Heaters 19a to 19b, 19c to 19d, 19e to 19d Nip roll 21 Winding body

Claims (8)

A reinforcing sheet in which carbon fiber filaments are laminated on at least one surface of a thin film sheet,
The carbon fiber filament group is opened, the filaments are arranged in parallel form in one direction, and are spaced every predetermined number,
The thin film sheet is at least one thin film sheet selected from non-woven fabric and paper;
The thin film sheet and the parallel carbon fiber filament group are integrated by adhesion ;
The space | interval opened every predetermined number of the said parallel-like carbon fiber filament group is 3-100 mm,
The relationship between the width | variety of the opened carbon fiber filament group and the said space | interval is 70 to 85% by the following formula, The reinforcement sheet characterized by the above-mentioned.
Ratio of width of opened carbon fiber filament group (%) = width of opened carbon fiber filament group (mm) / [width of opened carbon fiber filament group (mm) + spacing (mm) ] × 100 The reinforcing sheet according to claim 1, wherein the portions spaced at predetermined intervals are adhesion areas . The reinforcing sheet according to claim 1 or 2, wherein the carbon fiber filament group is a filament group obtained by opening the converged carbon fiber filament group.   The thickness of the said reinforcement sheet is 0.05-0.5 mm, The reinforcement sheet in any one of Claims 1-3.   The thickness of the said carbon fiber filament group is 0.03-0.15 mm, The reinforcement sheet in any one of Claims 1-4. The mass per unit area of the said reinforcement sheet is 30-150 g / m < ² >, The reinforcement sheet in any one of Claims 1-5. It is a manufacturing method of the reinforcement sheet in any one of Claims 1-6, Comprising:
Open the carbon fiber filament groups and arrange them so that each filament is parallel in one direction,
An adhesive is applied to one surface of the group of carbon fiber filaments arranged in parallel in one direction, a thin film sheet is superposed thereon, and the thin film sheet and the carbon fiber filaments are adhered and integrated. How to make a reinforcing sheet. It is a manufacturing method of the reinforcement sheet in any one of Claims 1-6, Comprising:
Open the carbon fiber filament groups and arrange them so that each filament is parallel in one direction,
A powdery adhesive is sprinkled on one surface of the carbon fiber filaments arranged in parallel in one direction, and a thin film sheet is superposed thereon and heated to bond and integrate the thin film sheet and the carbon fiber filaments. The manufacturing method of the reinforcement sheet characterized by doing.

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