JP7198348B2 - 積層体、及び三次元賦形積層体の製造方法 - Google Patents
積層体、及び三次元賦形積層体の製造方法 Download PDFInfo
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- JP7198348B2 JP7198348B2 JP2021511153A JP2021511153A JP7198348B2 JP 7198348 B2 JP7198348 B2 JP 7198348B2 JP 2021511153 A JP2021511153 A JP 2021511153A JP 2021511153 A JP2021511153 A JP 2021511153A JP 7198348 B2 JP7198348 B2 JP 7198348B2
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Description
層(Y)の厚さ(y)と層(X)の厚さ(x)との比(y/x)が3~40であり、
層(Y)の密度が0.2~0.6g/ccである積層体。
本発明において炭素繊維強化熱可塑性樹脂織物層(X)を構成する一方向性繊維強化樹脂シートは、熱可塑性樹脂と炭素繊維を含む炭素繊維強化熱可塑性樹脂組成物である。
融点及び/又はガラス転移温度が50~400℃の重合体(I)20~80質量%、及び
炭素繊維(C)20~80質量%
[但し(I)成分と(C)成分の合計を100質量%とする]
を含むことが好ましい。
プロピレン系樹脂(A) > プロピレン系樹脂(D) > プロピレン系樹脂(B)
本発明において発泡体層(Y)に含まれる樹脂(YA)[以下、「発泡体樹脂(YA)」と称す]は特に限定されず、公知の各種樹脂を使用できる。発泡体樹脂(YA)は、架橋樹脂でも良いし、無架橋体でも良い。発泡体樹脂(YA)の具体例としては、ポリエチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体、ポリスチレン系樹脂発泡体、ポリプロピレン系樹脂発泡体を外層に有するポリスチレン系樹脂発泡体等の熱可塑性樹脂発泡体が挙げられる。特に発泡体樹脂(YA)は、炭素繊維強化熱可塑性樹脂織物層(X)に含まれるマトリックス樹脂(XA)と同じ種類の熱可塑性樹脂で構成されることが好ましく、どちらもプロピレン系重合体であることが好ましい。このような構成とすることで、接着強度がより向上される傾向にある。なお、「同じ種類の熱可塑性樹脂」とは、マトリックス樹脂(XA)と発泡体層(Y)のいずれもが、例えばポリオレフィン樹脂を含むことを指す。この例でポリオレフィンとして、例えば、マトリックス樹脂(XA)がポリプロピレンを含み、発泡体層(Y)がポリブテンを含んでいても、いずれもポリオレフィン樹脂を含むため、マトリックス樹脂(XA)と発泡体層(Y)は「同じ種類の熱可塑性樹脂」を含む。ポリオレフィン樹脂の他にも、例えば、ポリカーボネート樹脂、スチレン系樹脂、ポリエステル樹脂、ポリフェニレンスルフィド樹脂(PPS樹脂)、変性ポリフェニレンエーテル樹脂(変性PPE樹脂)、ポリアセタール樹脂(POM樹脂)、液晶ポリエステル、ポリアリーレート、ポリメチルメタクリレート樹脂(PMMA)等のアクリル樹脂、塩化ビニル、ポリイミド(PI)、ポリアミドイミド(PAI)、ポリエーテルイミド(PEI)、ポリスルホン、ポリエーテルスルホン、ポリケトン、ポリエーテルケトン、ポリエーテルエーテルケトン(PEEK)、ポリオレフィン、変性ポリオレフィン、フェノール樹脂、フェノキシ樹脂、ポリアミド樹脂についても同様である。また、「どちらもプロピレン系重合体である」とは、マトリックス樹脂(XA)と発泡体層(Y)のいずれもが、プロピレンを構成単位として50質量%以上含む重合体を含むことを指す。ここで、「樹脂」と「重合体」は同じ概念であり、区別されない。
本発明の積層体は、炭素繊維と熱可塑性樹脂とを含み前記炭素繊維が長手方向に引き揃えられた一方向性繊維強化樹脂シートを縦糸及び横糸として含む織物を含む炭素繊維強化熱可塑性樹脂織物層(X)と、熱可塑性樹脂の発泡体層(Y)とを、層(X)/層(Y)/層(X)の順の層構成で有する。
本発明の三次元賦形積層体は、以上説明した本発明の積層体に三次元形状が付与されたものである。三次元形状の具体的な形態は特に制限されず、その表面に平面形状以外の形状が付与された場合はこれに該当する。
(一方向性繊維強化樹脂シートの織物の製造)
ポリプロピレンと炭素繊維を含有する一方向性炭素繊維強化樹脂シート(三井化学株式会社製、商品名TAFNEX、繊維体積分率(Vf)50%、厚さ0.16mm)を12.5mm幅となるよう切断した。そして、この切断後のテープ状の一方向性炭素繊維強化樹脂シートを用い、平織にて開口率が0.38%となるように、また経糸と緯糸の間隔が平均で約0.05mm~約1mmになるように製織し、一方向性繊維強化樹脂シートの織物を得た。
以上のようにして得た一方向性繊維強化樹脂シートの織物と、厚さ5mmのポリプロピレン発泡シート(三井化学東セロ株式会社製、商品名パロニア、密度0.3g/cc、発泡倍率3倍)を、各々縦157mm×横240mmの形状に切断した。そして、一方向性繊維強化樹脂シートの織物/ポリプロピレン発泡シート/一方向性繊維強化樹脂シートの順で積層し、さらに離型フィルムとしてポリイミドフィルムを最表面に配置した。そして、このポリイミドフィルムを介して、表面温度が約200℃のアイロンを用いて積層体の四隅(4つの角部分)のみを5秒間加熱した。その後、離型フィルムを剥がして、各層の四隅の界面のみが融着した積層体を得た。なお、この積層体の長手方向を0°とした場合、織物中の一方向性繊維強化樹脂シートの繊維の向きの角度は±45°とした。
長手方向の絞り量(Lw/Ld):1.0375
幅方向絞り量(Lw/Ld):1.0573=最大値
凹部の投影面積(S):40mm×40mm=1600mm2
凹部の深さ(N):7mm
凹部の曲げ半径(R)の最小値:1.0mm
織物中の一方向性繊維強化樹脂シートの繊維の向きの角度を0°及び90°に変更したこと以外は、実施例1と同様にして三次元賦形積層体を得た。各層の厚みは、0.32mm/4.36mm/0.32mmであった。ポリプロピレン発泡シートの層の厚み(y)と織物層の厚み(x)との比(y/x)は、13.63であった。
一方向性繊維強化樹脂シートの織物の製造において、平織に用いるシートの幅を25.0mmに変更し、開口率を0.09%に変更したこと以外は、実施例2と同様にして三次元賦形積層体を得た。各層の厚みは、0.32mm/4.36mm/0.32mmであった。ポリプロピレン発泡シートの層の厚み(y)と織物層の厚み(x)との比(y/x)は、13.63であった。
三次元賦形積層体の製造において、厚さ5mmのポリプロピレン発泡シートの代わりに、厚さ8mmのポリプロピレン発泡シート(三井化学東セロ株式会社製、商品名パロニア、密度0.3g/cc、発泡倍率3倍)を用いたこと以外は、実施例1と同様にして三次元賦形積層体を得た。各層の厚みは、0.32mm/7.36mm/0.32mmであった。ポリプロピレン発泡シートの層の厚み(y)と織物層の厚み(x)との比(y/x)は、23であった。
三次元賦形積層体の製造において、まず実施例4と同様にして、一方向性繊維強化樹脂シートの織物/ポリプロピレン発泡シート/一方向性繊維強化樹脂シートの順で積層した。そして、これを金型温度180℃の条件で熱プレス成形して、各層の界面が全体的に融着した積層体を得た。
三次元賦形積層体の製造において、厚さ5mmのポリプロピレン発泡シートの代わりに、厚さ3mmのポリプロピレン発泡シート(三井化学東セロ株式会社製、商品名パロニア、密度0.3g/cc、発泡倍率3倍)を用いたこと以外は、実施例1と同様にして三次元賦形積層体を得た。各層の厚みは、0.32mm/2.36mm/0.32mmであった。ポリプロピレン発泡シートの層の厚み(y)と織物層の厚み(x)との比(y/x)は、7.38であった。
三次元賦形積層体の製造において、スタンピング法の代わりにヒートアンドクール法を用いたこと以外は、実施例1と同様にして三次元賦形積層体を得た。具体的には、200℃の金型内に積層体を挿入し、積層体中の樹脂成分を徐々に軟化させながら金型を閉め、金型が完全に閉まった状態になってから圧力3MPaの条件で、2分間加熱プレス成形した。次いで、3MPaの圧力を保持したまま金型温度を90℃まで低下させ、90℃になった時点から2分間冷却した。その後、積層体を取り出して三次元賦形積層体を得た。各層の厚みは、0.32mm/4.36mm/0.32mmであった。ポリプロピレン発泡シートの層の厚み(y)と織物層の厚み(x)との比(y/x)は、13.63であった。
下側及び上側の一方向性繊維強化樹脂シートの織物の代わりに、織物と同じサイズ(縦157mm×横240mm)の4枚の一方向性繊維強化樹脂シートを用い、0°方向の一方向性繊維強化樹脂シート/90°方向の一方向性繊維強化樹脂シート/ポリプロピレン発泡シート/90°方向の一方向性繊維強化樹脂シート/0°方向の一方向性繊維強化樹脂シートの順で積層した。そして、これを実施例1と同様にしてスタンピング法による加工を行うことにより、三次元賦形積層体を得た。各層の厚みは、0.16mm/0.16mm/4.36mm/0.16mm/0.16mmであった。
下側及び上側の一方向性繊維強化樹脂シートの織物の代わりに、織物と同じサイズ(縦157mm×横240mm)の4枚の一方向性繊維強化樹脂シートを用い、45°方向の一方向性繊維強化樹脂シート/-45°方向の一方向性繊維強化樹脂シート/ポリプロピレン発泡シート/-45°方向の一方向性繊維強化樹脂シート/45°方向の一方向性繊維強化樹脂シートの順で積層した。そして、これを実施例1と同様にしてスタンピング法による加工を行うことにより、三次元賦形積層体を得た。各層の厚みは、0.16mm/0.16mm/4.36mm/0.16mm/0.16mmであった。
三次元賦形積層体の三次元形状部分及びその周辺を目視にて観察し、以下の基準で評価した。
「〇」:割れが無かった。あるいは5mm未満の微細な割れが有った。
「△」:5mm以上の割れが有った。
「×」:5mm以上の著しい割れが有り、割れた部分から発泡体層が見えていた。
三次元賦形積層体の三次元形状部分及びその周辺を目視にて観察し、以下の基準で評価した。
「〇」:しわが無かった。
「△」:5mm未満の微細なしわが有った。
「×」:5mm以上の著しいしわが有った。
成形前の長手方向の織物の長さを100として、成形後の三次元賦形積層体の織物の収縮量の割合を計算し、以下の基準で評価した。
「〇」:収縮量が成形前の長さの1%未満であった。
「△」:収縮量が成形前の長さの1%以上、5%未満であった。
「×」:収縮量が成形前の長さの5%以上であった。
光沢計(コニカミノルタホールディングス株式会社製、商品名GM-268)を用いて、光源はCIE標準光源Cの分光特性を有する白色光とし、受光角度60°における反射率のN=5の算術平均値を求め、以下の基準で評価した。
「◎」:算術平均反射率が50%以上であって、かつ最小反射率と最大反射率の差異が算術平均反射率の20%以内であった。
「〇」:算術平均反射率が50%以上であって、かつ最小反射率と最大反射率の差異が算術平均反射率の20%を超えていた。
「△」:算術平均反射率が10%以上、50%未満であった。
「×」:算術平均反射率が10%未満であった。
試験片(100×100mm)を、中央部分に撃芯が激突する様にASTM規格の高速面衝撃試験装置に固定し、以下の条件で最大衝撃力、最大衝撃力変位、最大衝撃力エネルギー及びパンクチャー点エネルギーを測定した。
撃芯径:1/2インチ
受け側リング径:1インチ
測定温度:室温
撃芯速度:3.57m/s
Y 発泡体層
Ld 三次元賦形積層体の三次元形状を含む部分の断面における端点と端点の直線長さ
Lw 三次元賦形積層体の三次元形状を含む部分の断面における断面周長
S 三次元賦形積層体の厚み方向に平面視した場合の三次元形状の投影面積
N 三次元賦形積層体の厚み方向における三次元形状の深さ
R 三次元賦形積層体の三次元形状における曲げ半径
Claims (10)
- 連続した炭素繊維と熱可塑性樹脂とを含み前記炭素繊維が長手方向に引き揃えられた一方向性繊維強化樹脂シートを縦糸及び横糸として含む織物を含む炭素繊維強化熱可塑性樹脂織物層(X)と、熱可塑性樹脂の発泡体層(Y)とを、層(X)/層(Y)/層(X)の順の層構成で有し、
層(Y)の厚さ(y)と層(X)の厚さ(x)との比(y/x)が3~40であり、
層(Y)の密度が0.2~0.6g/ccであり、
層(X)と層(Y)とは部分的に融着または接着されている積層体。 - 炭素繊維強化熱可塑性樹脂織物層(X)に含まれる織物の開口率が0.01~20%である請求項1に記載の積層体。
- 厚さが1~12mmである請求項1に記載の積層体。
- 炭素繊維強化熱可塑性樹脂織物層(X)に含まれるマトリックス樹脂(XA)と、発泡体層(Y)に含まれる樹脂(YA)とが同じ種類の樹脂である請求項1に記載の積層体。
- 炭素繊維強化熱可塑性樹脂織物層(X)に含まれるマトリックス樹脂(XA)と、発泡体層(Y)に含まれる樹脂(YA)とが何れもプロピレン系重合体である請求項1に記載の積層体。
- 発泡体層(Y)の発泡倍率が1.3~5倍である請求項1に記載の積層体。
- 輸送機器用途、家電装置用途及び建築用途から選ばれる用途の外装材に用いられる請求項1に記載の積層体。
- 積層体の長手方向を0°とした場合、炭素繊維強化熱可塑性樹脂織物層(X)に含まれる織物の一方向性繊維強化樹脂シートの繊維の向きの角度が±30~±60°である請求項1に記載の積層体。
- 請求項1に記載の積層体を熱プレス加工することにより三次元形状を付与する三次元賦形積層体の製造方法。
- 熱プレス加工がスタンピング法による加工である請求項9に記載の三次元賦形積層体の製造方法。
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