JPH02216237A - Production of fibrous composite material - Google Patents

Abstract

PURPOSE:To obtain a fibrous composite material which has high strength and can be readily produced and fabricated by allowing a specifically arranged line combination of high-melting continuous filaments and low-melting continuous filaments to pass through a hot dice under specific conditions and then being cooled. CONSTITUTION:High-melting continuous filaments as a reinforcing material 1 and low-melting continuous filaments as a matrix 2 are set in parallel lines in a specific arrangement to form a bundle 3. The bundle 3 is pulled out through a hot dice of a tapered cross section. The temperature of the dice is set lower than the melting point of the filament 1 and higher than that of the filament 2 so that the filaments 2 are fused to the filaments 1. After pulling out, the bundle is cooled down until the matrix is solidified to give the subject fibrous composite.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for producing a 1a fibrous composite material, and more specifically, a method for producing a 1a fibrous composite material, specifically a high-strength and versatile fibrous composite material using thermoplastic resin fibers as a matrix material. The invention relates to a method for manufacturing materials.

[Prior art] Composite materials that use synthetic resin as a matrix and high-strength fibrous materials as reinforcing materials have been widely used, and there are two types of composite materials: thermosetting resin-based and thermoplastic resin-based. It is possible to separate.

[Invention or problem to be solved] In both thermosetting resin and thermoplastic resin systems, the desired strength must be achieved unless the synthetic resin matrix and the reinforcing material are completely bonded. However, improving the adhesion between the two was an important issue.

Additionally, polymeric thermoplastic resins generally have poor fluidity and are extremely difficult to continuously mold using dies, which has also been a problem.

On the other hand, in molding using liquid resin or resin solution, it is necessary to squeeze out the impregnated excess resin with a squeegee roll or knife, which poses a problem in workability.

Furthermore, in the case of thermosetting resin products that are molded through a two-curing reaction, a process of reaction gas degassing is also required, which requires drying,
It also required heating time for curing. In addition, in thermoplastic resin products that are injection molded, only short fibers can be used as reinforcing fibers due to the performance of injection molding, and due to the limit fiber length, compared to using continuous length mia, the reinforcing fibers are There was also a strength problem in that the efficiency was only 50-90%.

The purpose of this invention is to solve these problems regarding composite materials, and to provide a method for manufacturing fibrous composite materials that have high strength, are easy to manufacture, and are easy to secondary process. .

[Means for Solving the Problems] The present invention provides a bundle of high melting point continuous fibers for reinforcing material and low melting point continuous fibers for matrix in a predetermined arrangement, and this bundle is arranged on the outlet side. The fibers have a tapered shape with a smaller cross-sectional area than the inlet side, and are drawn and passed through a die heated to a temperature above the melting temperature of the low melting point continuous fiber #a and below the melting temperature of the high melting point continuous fiber. The above-mentioned problem is solved by producing a fibrous composite material by heat-sealing a low-melting point continuous fiber to a high-melting point continuous fiber and cooling it after drawing.

[Function] The composite materials made in this way are used as raw materials, which are bundled and molded into various desired shapes. Compression molding by heating, such as the lamination method, FW method, and TW method, is also possible. It is possible.

It is also possible to form the fibers into bundles with other types of thermoplastic resin fibers, such as threads, ropes, tapes, pipes, sheets, etc.

[Examples] Examples of the present invention will be described below with reference to the drawings.

FIG. 1 shows an example of the method for manufacturing a fibrous composite material according to the present invention, in which 1 is a high melting point continuous Fa male used as a reinforcing material, and 2 is a low melting point continuous fiber used as a matrix. , low melting point continuous m fibers 2 are arranged and aligned in a predetermined pattern around a high melting point continuous ffl male 1 to form a bundle 3. The bundle 3 is passed through a tapered die 6 having a smaller cross-sectional area than either the outlet side 4 or the inlet side 5. This die 6 is heated above the melting temperature of the low melting point continuous fiber 2 and below the melting temperature of the high melting point continuous fiber 2, and the low melting point continuous fiber 2 is melted in this die 6 and bowed in 4 directions on the exit side. Accordingly, since the cross-sectional area of the die 6 is reduced, it is compressed, enters between the high melting point continuous fibers 81, and is adhesively fused thereto to form the matrix 9.

The fibrous composite material 7 drawn out from the outlet side 4 of the die 6 in this manner is cooled and solidified by the cooler 8.

In addition, in the figure, 12 is a bobbin, 13 is a focusing guide, 14 is a tension roll, and 15 is a winding bobbin.

The high melting point continuous edge H1 is used as a reinforcing material, and is made of metal ia male such as stainless steel, steel, copper, aluminum, inorganic fiber such as glass, ceramic, alumina, silicon carbide, or organic fiber such as aramid or carbon fiber. I can do it.

Also, can any thermoplastic resin fiber be used for the low melting point continuous edge ftn2? Polyethylene, polypropylene,
Polyester, vinyl chloride, molybdenum chloride, etc. can be suitably used. Also, high melting point continuous fiber 1 and low melting point continuous fiber 2
In order to improve the fusion bond with the high melting point continuous fiber J, the high melting point continuous fiber J may be subjected to a surface treatment in advance.

An actual prototype example is as follows.

High melting point continuous edge m1 of two φ10 stainless steel fibers
, 1218 m93 polypropy wood with a diameter of 2.5 mm were used as the low melting point continuous m fibers 2, and arranged as shown in FIG. 2 to form a bundle 3. Then, this bundle 3 was passed through a die 6 heated to 175° C., which is the melting point of polypropylene, and then cooled to room temperature to obtain a fibrous composite material having the cross-sectional shape shown in FIG. In addition, Fig. 4 shows A- in Fig. 3.
It is an A-line sectional view.

The cross-sectional shape of the die 6 used in this example is oval, or may be circular, triangular, polygonal, or other cross-sectional shapes.
It is also possible to use one with a mouth-shaped cross section. or,
A cross-sectional shape with a triangular or polygonal side or a concave interior may also be used.

In addition, instead of the usual general die, as shown in FIGS. 5 and 6, a pair of rollers 10.10 that are in contact with each other are provided with grooves 11.11 having semicircular cross sections at opposing positions on the circumferential surface of the rollers 10.10. It is also possible to use a modified die 6' in which rollers 10.10 are heated and rotated to fuse and shape the bundle 3 while passing through the grooves 11.11.

By changing the shape of the groove 11 in this irregularly shaped die 6', it is also possible to produce an irregularly shaped fibrous composite material 7' as shown in FIG.

[Effects of the invention] In this method for producing a composite material, all raw materials are in the form of fibers, which are easily available and inexpensive, and are not powdered, so the stock environment conditions are not severe and handling is easy. .

Continuous production of long fibers is possible, no semi-drying or uncured heating time is required, and production speed is not limited.

It does not require large-scale production equipment, it is easy to change production, there is little loss of raw materials, there is no need for standstill time during start-up, and it is possible to produce a wide variety of products in small quantities.

It is possible to combine several types of fibers, and does not require skilled technology to manufacture.

Since it is based on melt bonding of thermoplastic resin, it does not require strict resin adjustment or impregnation condition control unlike when using a resin solution or liquid resin.

It is also possible to mold high molecular weight thermoplastic resins with poor fluidity.

Since it is melt pultrusion molding using continuous fa fibers, the limit is m! a
Strength can be increased regardless of length.

By changing the cross-sectional shape of the die or using irregularly shaped dies, products with arbitrary cross-sectional shapes can be obtained.

It has the following effects and can be used for a very wide range of purposes by performing secondary molding.

[Brief explanation of the drawing]

The drawings relate to an embodiment of the mmI-like composite material according to the present invention, and FIG. 1 is a side view of a manufacturing apparatus for explaining the process, FIG. 2 is a cross-sectional view of the bundle, and FIG. 3 is a cross-sectional view of the bundle. A cross-sectional view of the final product, FIG. 4, is a cross-sectional view taken along the line A--A in FIG. 3. Further, FIG. 5 is a side view of an irregularly shaped die used in another example, FIG. 6 is a front view thereof, and FIG. 7 is a side view of a fibrous composite material manufactured using this irregularly shaped die. 1... High melting point continuous #a, 1dIO... Roller 2.
... Low melting point continuous @ [11... Groove 3... Focusing body 12... Bobbin 4... Outlet side 13... Focusing guide 5... Inlet side
14...Tension roll 6...Dice
15... Winding bobbin 7... Fibrous composite material 8... Cooler 9... Matrix 1 Figure 2 Figure 4 Figure 50 Figure 6 Figure 7

Claims (1)

[Claims] The high-melting point continuous fibers for the reinforcing material and the low-melting point continuous fibers for the matrix are arranged in a predetermined arrangement to form a bundle, and the bundle has a tapered shape with the outlet side having a smaller cross-sectional area than the inlet side. , drawing and passing through a die heated to a temperature above the melting temperature of the low-melting point continuous fiber and below the melting temperature of the high-melting point continuous fiber, heat-sealing the low-melting point continuous fiber to the high-melting point continuous fiber in the die, and drawing. A method for producing a fibrous composite material, which comprises cooling the material afterwards.