JPH01104851A - Composite molding sheet - Google Patents

Composite molding sheet

Info

Publication number
JPH01104851A
JPH01104851A JP62262182A JP26218287A JPH01104851A JP H01104851 A JPH01104851 A JP H01104851A JP 62262182 A JP62262182 A JP 62262182A JP 26218287 A JP26218287 A JP 26218287A JP H01104851 A JPH01104851 A JP H01104851A
Authority
JP
Japan
Prior art keywords
heat
fibers
fiber
composite
resistant
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.)
Pending
Application number
JP62262182A
Other languages
Japanese (ja)
Inventor
Kiyohide Hayashi
清秀 林
Shigeharu Sugihara
杉原 重治
Masamutsu Yamane
正睦 山根
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyobo Co Ltd
Original Assignee
Toyobo Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Toyobo Co Ltd filed Critical Toyobo Co Ltd
Priority to JP62262182A priority Critical patent/JPH01104851A/en
Publication of JPH01104851A publication Critical patent/JPH01104851A/en
Pending legal-status Critical Current

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  • Woven Fabrics (AREA)

Abstract

PURPOSE: To obtain a composite molding sheet excellent in impregnability with thermoplastic resin and suitable for reinforced plastic molded products with high mechanical strength and high modulus such as mechanical parts and pressure vessels by knitting composite yarns each comprising a specific amount of heat-resistant fiber and thermoplastic organic fiber. CONSTITUTION: This composite molding sheet is obtained by knitting composite yarns each of which is produced by arranging (A) thermoplastic organic fibers, (e.g. polyethylene, nylon 66) and (B) 5-80 wt.% of heat-resistant fibers >=450 deg.C in heat resistance, (e.g. aramid fibers, glass fibers) in parallel with each other followed by plying.

Description

【発明の詳細な説明】 (産業上の利用分野) この発明は、自動車その他の各種機械部品、圧力容器お
よびパイプ等の高強度と高弾性率を備えた強化プラスチ
ック製品を成形するのに適した複合成形用シートに関す
るものである。
[Detailed Description of the Invention] (Field of Industrial Application) The present invention is suitable for molding reinforced plastic products with high strength and high elastic modulus such as automobiles and various other mechanical parts, pressure vessels, and pipes. This invention relates to a sheet for composite molding.

(従来の技術) 熱可塑性合成樹脂と強化材用繊維とからなる強化プラス
チックでは、溶融粘度が高い熱可塑性合成樹脂を上記の
強化材用繊維に均一に、かつボイドが生じないように含
浸させることが必要である。
(Prior art) For reinforced plastics made of thermoplastic synthetic resin and reinforcing fibers, it is necessary to impregnate the above-mentioned reinforcing fibers with the thermoplastic synthetic resin having a high melt viscosity uniformly and without creating voids. is necessary.

このような要求を満たすための方法として、ガラス繊維
ストランドを静電気によって開繊し、この開繊したガラ
ス繊維に熱可塑性合成樹脂の粉末を散布して付着させ、
しかるのち加熱により上記の粉末を溶融してテープ状ス
トランドを成形する方法(特公昭47−36467号公
報参照)、および熱可塑性合成樹脂の粉末を付着させた
強化材用繊維のストランドに柔軟性熱可塑性合成樹脂を
コーティングして柔軟性ストランドとし、この柔軟性ス
トランドで織物を製造し、しかるのち加熱゛により上記
の粉末およびコーティング層を溶融して板状に成形する
方法(特開昭60−36156号公報参照)が知られて
いる。
As a method to meet these demands, glass fiber strands are opened using static electricity, and thermoplastic synthetic resin powder is spread and adhered to the opened glass fibers.
Thereafter, the above powder is melted by heating to form a tape-shaped strand (see Japanese Patent Publication No. 47-36467), and a reinforcing fiber strand to which thermoplastic synthetic resin powder is attached is subjected to flexibility heat. A method of coating a plastic synthetic resin to form a flexible strand, manufacturing a textile using the flexible strand, and then melting the powder and coating layer by heating and forming it into a plate shape (Japanese Patent Laid-Open No. 60-36156) (Refer to Publication No. 1) is known.

(発明が解決しようとする問題点) 従来は、熱可塑性合成樹脂を粉末にして用いていたので
、熱可塑性合成樹脂の含浸性を良くするためには、上記
の粉末を粒径がミクロンオーダーの微粉末にする必要が
あり、かつ強化材用繊維の開繊、上記粉末の散布付着、
溶融、被覆等の極めて複雑な工程を必要とし、しかもシ
ート状の強化プラスチックを得るためには、樹脂を含浸
したストランド、すなわちプリプレグをたて糸およびよ
こ糸に用いて製織することが必要であり、上記プリプレ
グが通常の繊維糸条に比して硬いため製織およびその準
備が極めて困難であった。
(Problem to be solved by the invention) Conventionally, thermoplastic synthetic resins have been used in the form of powder, so in order to improve the impregnating properties of thermoplastic synthetic resins, it is necessary to use powders with particle sizes on the order of microns. It is necessary to make it into a fine powder, and it is necessary to open the reinforcing fiber, spread the powder, and apply it.
This requires extremely complicated processes such as melting and coating, and in order to obtain sheet-shaped reinforced plastics, it is necessary to weave resin-impregnated strands, that is, prepreg, as warp and weft yarns. Since it is harder than ordinary fiber threads, it is extremely difficult to weave and prepare it.

この発明は、熱可塑性合成樹脂の含浸性が極めて良好で
あり、かつ補強効率の高い強化プラスチックシートを容
易に、かつ安価に成形することができる複合成形用シー
トを提供するものである。
The present invention provides a sheet for composite molding, which has extremely good impregnability with a thermoplastic synthetic resin and can be easily and inexpensively molded into a reinforced plastic sheet with high reinforcement efficiency.

(問題点を解決するための手段) この発明の複合成形用シートは、熱可塑性有機繊維およ
び耐熱性が450℃以上の耐熱性繊維の引揃えおよび/
または合撚の複合糸を用いてgIJl!!されており、
上記耐熱性繊維の含有量が全体の5〜80%であること
を特徴とする。
(Means for Solving the Problems) The composite molding sheet of the present invention comprises thermoplastic organic fibers and heat-resistant fibers having a heat resistance of 450° C. or higher, arranged and/or
Or use gIJl! with composite yarn of ply twist! ! has been
It is characterized in that the content of the heat-resistant fibers is 5 to 80% of the total content.

この発明で使用する熱可塑性有機lItは、ポリエチレ
ン、ポリプロピレン等のポリオレフィン類、ナイロン6
、ナイロン66等のポリアミド類、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
ル類、ポリフェニレンスルフィド、ポリエーテルエーテ
ルケトン等の熱可塑性合成樹脂からなる繊維である。
The thermoplastic organic materials used in this invention include polyolefins such as polyethylene and polypropylene, nylon 6
, polyamides such as nylon 66, polyesters such as polyethylene terephthalate and polybutylene terephthalate, and thermoplastic synthetic resins such as polyphenylene sulfide and polyether ether ketone.

また、耐熱性が450℃以上の耐熱性繊維とは、450
℃よりも低い温度では熱分解も溶融もしない繊維であり
、アラミド繊維、ガラス繊維および炭素繊維が例示され
る。
In addition, heat-resistant fibers with a heat resistance of 450°C or higher are 450°C or higher.
It is a fiber that neither thermally decomposes nor melts at temperatures lower than °C, and examples thereof include aramid fiber, glass fiber, and carbon fiber.

上記の熱可塑性有機繊維および耐熱性繊維は。The above thermoplastic organic fibers and heat-resistant fibers.

これらの繊維からなる少なくとも2種の糸条を引揃える
か、または引揃え後に合撚して使用される。
At least two types of yarns made of these fibers are used by aligning them or by twisting them together after aligning them.

なお、熱可塑性有機繊維および耐熱性繊維の混合比は、
シートとしたときの耐熱性繊維の含有率5〜80重量%
、好ましくは30〜70重景%、および後記するシート
における糸使い等によって決定されるが、上記耐熱性繊
維糸条のデニール数およびフィラメント数は、それぞれ
100〜1000デニールおよび10〜100フイラメ
ントが好ましく、熱可塑性有機繊維糸条のデニール数お
よびフィラメント数は、それぞれ100〜10000デ
ニールおよびlO〜1000フィラメントが好ましい。
The mixing ratio of thermoplastic organic fiber and heat-resistant fiber is
Heat-resistant fiber content 5 to 80% by weight when made into a sheet
The denier number and filament number of the heat-resistant fiber yarn are preferably 100 to 1000 deniers and 10 to 100 filaments, respectively, although the denier number and filament number of the heat-resistant fiber yarn are preferably determined by 30 to 70 weight percent, and the use of yarn in the sheet to be described later. The denier number and filament number of the thermoplastic organic fiber yarn are preferably 100 to 10,000 deniers and 10 to 1,000 filaments, respectively.

上記の引揃えおよび/または合撚の複合糸を用いて織成
される織物の組織は、平織、綾織、朱子織の三元組織の
ほか、その誘導組織である斜子織、うね織、破れ綾織、
杉M111などが例示される。また、一般にガラス繊維
を用いた強化布の組織として用いられる粗目の平織、か
らみ織0.2模紗織等、用途に応じて種々の組織を選択
して使用することができる。なお、たて糸、よこ糸の双
方に上記の複合糸を用いる以外に、たて糸、よこ糸の一
方、好ましくはたて糸に上記の複合糸を用い、この複合
糸中の熱可塑性有機繊維と同一の繊維からなる糸条をよ
こ糸に用いてもよい。また、上記の複合糸を用いて経編
、丸編、横櫂などの任意組織の編地を編成してもよく、
経編の場合は、上記の複合糸で編目ループを形成するこ
となく上記複合糸をレイインまたはタックイン等の方法
で挿入することができる。
Textiles woven using the above-mentioned aligned and/or twisted composite yarns include ternary structures such as plain weave, twill weave, and satin weave, as well as their guided structures such as diagonal weave, ridge weave, Torn twill,
An example is cedar M111. In addition, various textures can be selected and used depending on the purpose, such as coarse plain weave and leno weave 0.2 pattern gauze, which are generally used as the texture of reinforced cloth using glass fibers. In addition to using the above-mentioned composite yarn for both the warp and the weft, the above-mentioned composite yarn is used for either the warp or the weft, preferably the warp, and the yarn is made of the same fiber as the thermoplastic organic fiber in the composite yarn. The strips may also be used as weft threads. In addition, the above-mentioned composite yarn may be used to knit fabrics with arbitrary structures such as warp knitting, circular knitting, horizontal oar, etc.
In the case of warp knitting, the composite yarn can be inserted by a method such as lay-in or tuck-in without forming a stitch loop with the composite yarn.

(作用) 上記のシートを所望の大きさに裁断し、目的とする成形
品の重量に等しくなる枚数を重ねてブランクとし、熱可
塑性有機繊維の軟化点よりも高い温度、好ましく熱可塑
性有機繊維の溶融温度に予熱し、これを金型に取付けて
プレスすることにより、所望の形状の成形品、すなわち
強化プラスチック製品が得られる。ただし、耐熱性繊維
の含有率が全体の5重量%未満の場合は、少な過ぎて上
記最終製品における補強効率が低くなり、反対に80重
量%超ではボイド率が増大して不適当である。なお、プ
レス圧力は、投影面積に対して50〜1.50kg/a
dが必要であり、加圧は1〜2秒で速く行なうことが好
ましい、また、金型の温度は、熱可塑性有機繊維の融点
から融点以下50℃の範囲が好ましく、冷却時間は成形
品の厚みが最大の部分によって決定される。
(Function) Cut the above sheet into a desired size, stack a number of sheets equal to the weight of the desired molded product to form a blank, and prepare the sheet at a temperature higher than the softening point of the thermoplastic organic fiber, preferably at a temperature higher than the softening point of the thermoplastic organic fiber. By preheating the material to a melting temperature, attaching it to a mold, and pressing it, a molded product of a desired shape, that is, a reinforced plastic product, can be obtained. However, if the content of heat-resistant fibers is less than 5% by weight of the total, it is too small and the reinforcing efficiency in the final product will be low, while if it exceeds 80% by weight, the void ratio will increase, making it unsuitable. Note that the press pressure is 50 to 1.50 kg/a relative to the projected area.
d is required, and it is preferable to pressurize quickly in 1 to 2 seconds. Also, the temperature of the mold is preferably in the range from the melting point of the thermoplastic organic fiber to 50°C below the melting point, and the cooling time is set according to the temperature of the molded product. The thickness is determined by the largest part.

しかして、織物の場合に、たて糸およびよこ糸の一方1
例えばたて糸に上記の引揃えおよび/または合撚の複合
糸を用い、よこ糸に上記複合糸中の熱可塑性有機繊維の
みからなる糸条を用いたときは、得られた複数枚の織物
のたて糸の方向を揃えて重ねることにより一方向強化板
が得られ、交互に向きを変えて積層することにより斜交
積層板が得られる。また、経編の場合に上記複合糸をた
て方向に挿入すると、たて方向に高度に強化された成形
品が得られ、たて糸挿入間によこ糸挿入間を併用するこ
とにより、たて方向およびよ二方向の双方が高度に強化
される。なお、丸編や横編においては、たて編に比べて
よこ方向の方向性が強いので、特によこ糸を挿入しなく
ても、よ二方向の一方向強化板が得られる。
Therefore, in the case of textiles, one of the warp and weft yarns is
For example, when the warp is made of the above-mentioned aligned and/or plied composite yarn, and the weft is made of only the thermoplastic organic fibers in the composite yarn, the warp of the resulting plurality of woven fabrics is By stacking them in the same direction, a unidirectional reinforced board can be obtained, and by stacking them in alternating directions, a diagonal laminate can be obtained. In addition, in the case of warp knitting, if the above composite yarn is inserted in the warp direction, a molded product that is highly strengthened in the warp direction can be obtained, and by using the weft yarn insertion interval between the warp yarn insertions, the warp direction and Both directions are highly strengthened. In addition, in circular knitting and flat knitting, the directionality in the weft direction is stronger than in warp knitting, so a unidirectional reinforced plate in the weft direction can be obtained without inserting any weft threads.

(実施例) 耐熱性繊維としてアラミド繊維糸条(デュポン社製、ケ
ブラー49,380デニール、260フイラメント)を
、また熱可塑性有機繊維としてポリエチレンテレフタレ
ート(フェノール/テトラクロルエタン=、60/40
の混合溶媒中、30℃で測定した極限粘度が0.6)か
らなる繊維糸条(450デニール、144フイラメント
)をそれぞれ用い、これらを引揃えたのち100回/m
の撚数で合撚し、800デニールの複合糸(引揃え合撚
糸)を得た。この複合糸をたて糸およびよこ糸に用い、
たて糸密度19.7本/a11、よこ糸密度19.7本
/a11の平織物を製織し、この平織物から縦20a1
1.横20amの試料を切り取り、これを3枚積層して
ブランクとし、80℃、 0.1msHg以下の条件で
16時間真空乾燥を行ない、次いであらかじめ300℃
に加熱した金型に上記の積層シートを取付け、軽荷重で
3〜5分間予熱し、溶融した後、50〜70kg/、c
dの圧力で加熱圧縮成形を行なった。次いで、加圧下で
60℃まで急冷した後、金型を開けることにより、ポリ
エチレンテレフタレートからなり、アラミド繊維で強化
された厚さ1.5nmの強化積層板を得た。この強化積
層板におけるアラミド繊維の含有率は40重量%であり
、ボイド率は3%以下であった。また、上記の強化積層
板をASTM・D・3039に準拠して引張試験を行な
ったところ、950〜1050MPaの引張強度を有し
、かつ等方向であり、外観上も問題がなかった。
(Example) Aramid fiber yarn (manufactured by DuPont, Kevlar 49,380 denier, 260 filament) was used as the heat-resistant fiber, and polyethylene terephthalate (phenol/tetrachloroethane = 60/40) was used as the thermoplastic organic fiber.
In a mixed solvent of
The composite yarn (drawn and twisted yarn) of 800 denier was obtained. This composite yarn is used for the warp and weft,
A plain woven fabric with a warp density of 19.7 threads/a11 and a weft thread density of 19.7 threads/a11 is woven, and from this plain woven fabric warp 20 a1
1. A sample with a width of 20 am was cut, three sheets were stacked together to form a blank, and vacuum dried at 80°C and 0.1msHg or less for 16 hours, and then preheated at 300°C.
Attach the above laminated sheet to a mold heated to
Heat compression molding was performed at a pressure of d. Next, after rapidly cooling to 60° C. under pressure, the mold was opened to obtain a reinforced laminate made of polyethylene terephthalate and reinforced with aramid fibers and having a thickness of 1.5 nm. The aramid fiber content in this reinforced laminate was 40% by weight, and the void rate was 3% or less. Further, when the above-mentioned reinforced laminate was subjected to a tensile test in accordance with ASTM D 3039, it had a tensile strength of 950 to 1050 MPa, was isodirectional, and had no problems in appearance.

(発明の効果) この発明の複合成形用シートは、熱可塑性有機繊維と耐
熱性繊維の引揃えおよび/または合撚の複合糸を用いた
編織物であるから、従来の熱可塑性合成樹脂粉末を付着
した補強用繊維糸条に比べて複合糸の製造が容易であり
、しかも従来の編織技術でシートを製造することができ
、かつ熱可塑性有機繊維の軟化点よりも高い温度で溶融
成形することにより、ボイドの少ない良好な成形品を製
造することができる。
(Effects of the Invention) The composite molding sheet of the present invention is a knitted fabric using composite yarns of thermoplastic organic fibers and heat-resistant fibers aligned and/or plied. Composite yarns are easier to manufacture than attached reinforcing fiber threads, sheets can be manufactured using conventional knitting and weaving techniques, and they can be melt-molded at a temperature higher than the softening point of thermoplastic organic fibers. Accordingly, a good molded product with few voids can be manufactured.

特許出願人  東洋紡績株式会社 代理人 弁理士  吉 1)了 司Patent applicant: Toyobo Co., Ltd. Agent: Patent Attorney Yoshi 1) Tsukasa Ryo

Claims (1)

【特許請求の範囲】 〔1〕熱可塑性有機繊維および耐熱性が450℃以上の
耐熱性繊維の引揃えおよび/または合撚の複合糸を用い
て編織されており、上記耐熱性繊維の含有量が全体の5
〜80重量%を占めていることを特徴とする複合成形用
シート。 〔2〕耐熱性繊維としてアラミド繊維、ガラス繊維およ
び炭素繊維のいずれか一種以上が用いられている特許請
求の範囲第1項記載の複合成形用シート。
[Scope of Claims] [1] Woven using a composite yarn of thermoplastic organic fibers and heat-resistant fibers with a heat resistance of 450° C. or higher, which are aligned and/or twisted together, and the content of the heat-resistant fibers is is the total 5
A sheet for composite molding, characterized in that it accounts for ~80% by weight. [2] The sheet for composite molding according to claim 1, wherein at least one of aramid fiber, glass fiber, and carbon fiber is used as the heat-resistant fiber.
JP62262182A 1987-10-16 1987-10-16 Composite molding sheet Pending JPH01104851A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP62262182A JPH01104851A (en) 1987-10-16 1987-10-16 Composite molding sheet

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP62262182A JPH01104851A (en) 1987-10-16 1987-10-16 Composite molding sheet

Publications (1)

Publication Number Publication Date
JPH01104851A true JPH01104851A (en) 1989-04-21

Family

ID=17372207

Family Applications (1)

Application Number Title Priority Date Filing Date
JP62262182A Pending JPH01104851A (en) 1987-10-16 1987-10-16 Composite molding sheet

Country Status (1)

Country Link
JP (1) JPH01104851A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013253343A (en) * 2012-06-07 2013-12-19 Asahi Kasei Fibers Corp Composite yarn

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6045632A (en) * 1983-08-19 1985-03-12 帝人株式会社 Composite fiber structure for thermal molding
JPS6134244A (en) * 1984-07-26 1986-02-18 東レ株式会社 Fabric for reinforcing resin and its production
JPS61130345A (en) * 1984-11-19 1986-06-18 フイリツプス ペトロリユーム コンパニー Production of fiber reinforced thermoplastic article
JPS626932A (en) * 1985-07-01 1987-01-13 東レ株式会社 Production of reinforcing fiber fabric

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6045632A (en) * 1983-08-19 1985-03-12 帝人株式会社 Composite fiber structure for thermal molding
JPS6134244A (en) * 1984-07-26 1986-02-18 東レ株式会社 Fabric for reinforcing resin and its production
JPS61130345A (en) * 1984-11-19 1986-06-18 フイリツプス ペトロリユーム コンパニー Production of fiber reinforced thermoplastic article
JPS626932A (en) * 1985-07-01 1987-01-13 東レ株式会社 Production of reinforcing fiber fabric

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013253343A (en) * 2012-06-07 2013-12-19 Asahi Kasei Fibers Corp Composite yarn

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