JPH0516138A - Fiber reinforced sheet and its manufacture - Google Patents

Abstract

PURPOSE:To manufacture a fiber reinforced sheet in which continuous reinforced fibers arranged in one direction are not flowed at the time of molding and retained at the given positions. CONSTITUTION:Fiber reinforced resin layers comprising reinforcing fibers f5 of 5mm length all over disposed at random on thermoplastic resin B are laminated integrally into the sandwich shape on both faces of a fiber reinforced resin layer in which continuous reinforcing fibers F3 are arranged in one direction on thermoplastic resin A. As the thermoplastic resin A, the resin with melting viscosity larger than that of thermoplastic resin B is used.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a tough plate material,
For stamping sheet, which is a press forming material for obtaining various products, is used for stamping forming molded parts that require mechanical strength in one direction, such as reinforcing materials for automobile bumpers and doors. And a manufacturing method thereof.

[0002]

2. Description of the Related Art As a fiber-reinforced sheet, there has been known a fiber-reinforced sheet obtained by impregnating a thermoplastic resin into a laminate of (a) reinforced long fibers aligned in one direction and a long-fiber mat. (See Japanese Laid-Open Patent Publication No. 62-240514).

Further, as a method for producing a fiber reinforced sheet,
(B) Mixing reinforced short fibers and powdered thermoplastic resin in a jet stream of compressed air and dropping them on a net to accumulate them, and then transferring the aggregates to a moving endless belt, heating and pressurizing and cooling. To form a sheet (JP-A-59-49929)
(See Japanese Patent Publication No. 2), and (c) reinforced short fibers and powdered thermoplastic resin are mixed in a container while keeping them in a fluidized state, taken out of the container, dropped on a moving endless belt, and accumulated, A method is known in which a sheet is fed into a gap between moving upper and lower endless belts which are opposed to each other at a predetermined interval, heated and pressed, and then cooled to form a sheet (JP-A-62-2).
08914 publication).

[0004]

In the fiber reinforced sheet of the above (a), a laminate of reinforced long fibers aligned in one direction and a long fiber mat is impregnated with the same thermoplastic resin. Therefore, when press molding is performed using this sheet, the thermoplastic resin of the long fiber reinforced layer aligned in one direction flows substantially similarly to the thermoplastic resin of the long fiber mat reinforced layer. As a result, the long fibers in the actual molded product are not aligned in the intended direction, so that the mechanical strength is partially reduced. In addition, there is a problem that the control cannot be performed because the location and degree of the decrease vary.

Further, in the above-mentioned method (2) for producing a fiber-reinforced sheet, the reinforcing short fibers having different specific gravities and the powdery thermoplastic resin are mixed under a stream of air and are dropped and accumulated. There is a problem that the distribution becomes non-uniform and the physical properties of the obtained sheet vary greatly. Further, in the above method (c) of producing a fiber-reinforced sheet, the reinforcing short fibers and the powdery thermoplastic resin are mixed in a container, so that the sheet cannot be continuously obtained, resulting in poor productivity. There is a problem.

An object of the present invention is to provide a fiber-reinforced sheet in which continuous reinforcing fibers aligned in one direction do not flow at the time of molding and maintain a predetermined position, and this sheet has high strength and does not cause variations in physical properties. Another object of the present invention is to provide a method capable of being manufactured with high productivity.

[0007]

The invention of claim 1 is a fiber reinforced sheet, comprising a thermoplastic resin (A) in which continuous reinforcing fibers are arranged in one direction (a fiber reinforced resin layer ( A) and a fiber reinforced resin layer (i) in which reinforcing fibers having a length of 5 mm or more are arranged in a random state in the length direction in a thermoplastic resin (B) are integrally laminated to have a melt viscosity The thermoplastic resin (A) is larger than the thermoplastic resin (B).

A second aspect of the present invention is a fiber reinforced sheet, comprising a fiber reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A),
A thermoplastic resin (B) is obtained by laminating and integrating a thermoplastic resin (B) with a fiber-reinforced resin layer (II) in which reinforcing fibers having a length of 5 mm or more are randomly arranged in the longitudinal direction.
Is a crosslinked thermoplastic resin.

A third aspect of the present invention is a fiber reinforced sheet, comprising a fiber reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A),
The thermoplastic resin (B) is laminated and integrated with a fiber-reinforced resin layer (i) in which reinforcing fibers having a length of 5 mm or more are randomly arranged in the longitudinal direction, and the fiber-reinforced resin layer (a) is formed. The net-shaped reinforcing material is built in.

A fourth aspect of the present invention is the method for producing the fiber-reinforced sheet according to the first aspect, wherein a reinforcing fiber bundle composed of a large number of continuous monofilaments is arranged in upper, middle and lower layers of the powdery thermoplastic resin. Passing through the fluidized bed and adhering the powdered thermoplastic resin to each filament of the fiber bundle, and the gap between the upper and lower endless belts that are made to face each other with the intermediate continuous resin-attached fiber bundle at a predetermined interval. And the step of continuously feeding to the upper and lower resin-attached fiber bundles are cut into 5 mm or more, respectively, and the upper cut resin-attached fiber bundles are dropped and accumulated on the intermediate continuous resin-attached fiber bundle,
The lower cut resin-adhered fibers are dropped onto the feeding part into the gap between the upper and lower endless belts and accumulated, and both aggregates are continuously fed into the gap between the upper and lower endless belts as the middle continuous resin-adhered fiber bundle moves. Step and step of passing through the heating area and the cooling area to form a sheet while sandwiching the upper and middle cut resin-adhered fiber aggregates through the intermediate continuous resin-adhered fiber bundle with both endless belts And a thermoplastic resin (A) having a higher melt viscosity than the thermoplastic resin (B) of the upper and lower fluidized beds is used as the thermoplastic resin (A) of the middle fluidized bed.

If the length of the reinforcing fiber of the fiber-reinforced resin layer (i) is less than 5 mm, the reinforcing effect of the fiber will not be obtained, so the length is set to 5 mm or more. Generally, the longer the reinforcing fiber is, the higher the reinforcing effect is, so the upper limit of the length is not particularly limited, but the dispersibility may decrease depending on the method of forming the fiber-reinforced resin layer (i),
Since the surface characteristics of the stamping molded product obtained from the fiber reinforced sheet may deteriorate, it is usually 100 mm.
Hereinafter, it is preferably 50 mm.

As the reinforcing fibers, fibers that are thermally stable at the melting temperature of the thermoplastic resin used are used. Specific examples thereof include glass fibers, carbon fibers, silicon / titanium / carbon fibers, boron fibers, fine metal fibers, aramid fibers, liquid crystal polymer fibers, polyester fibers, and polyamide fibers.

The diameter of the monofilament is preferably 1 to 50 μm. When using a large number of continuous filaments as a reinforcing fiber bundle, a sizing agent may or may not be used. However, when the sizing agent is used, if the amount of the sizing agent attached exceeds 1% by weight,
It becomes difficult to separate the fiber bundles into monofilament units in the fluidized bed, and the impregnating ability of the thermoplastic resin between the monofilaments decreases.

The reinforcing fiber bundle is in the form of a strand or a roving in which hundreds to thousands of continuous monofilaments are formed. And this reinforcing fiber bundle, considering the width, thickness, manufacturing speed, etc. of the fiber-reinforced sheet to be produced,
Usually used in parallel.

The reinforcing fibers in the fiber-reinforced resin layer (a) and the reinforcing fibers in the fiber-reinforced resin layer (ii) may be of the same kind or of different kinds, and the content ratio of the reinforcing fibers may be the mechanical strength and the sheet. Is appropriately determined according to the shape of the molded product to be molded.

As the thermoplastic resins (A) and (B), any resin that is melted and softened by heating can be used. For example,
Polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamide, polyethylene terephthalate,
Polybutylene terephthalate, polycarbonate, polyvinylidene fluoride, polyphenylene sulfide, polyphenylene oxide, polyether sulfone, polyether ether ketone and the like are used.

Further, a copolymer or graft resin containing the above-mentioned thermoplastic resin as a main component, for example, ethylene-vinyl chloride copolymer, vinyl acetate-ethylene copolymer, vinyl acetate-
Vinyl chloride copolymer, urethane-vinyl chloride copolymer,
Acrylonitrile-butadiene-styrene copolymer, acrylic acid-modified polypropylene, maleic acid-modified polyethylene, etc. may also be used. The above resins may be blended and used. Then, additives such as a stabilizer, a lubricant, a processing aid, a plasticizer, and a colorant may be blended with the thermoplastic resin.

Further, both a thermoplastic resin obtained in powder form at the time of polymerization and a thermoplastic resin made into powder form by a pulverizer can be used. The average particle size is preferably less than 2 mm. When the average particle size exceeds 2 mm, it becomes difficult to uniformly impregnate the monofilaments of the reinforcing fiber bundle in the fluidized bed. The thermoplastic resin (A) and the thermoplastic resin (B) may be the same or different.

According to the first aspect of the invention, however, among the above thermoplastic resins, the thermoplastic resin (A) having a relatively high melt viscosity during heating in press molding is used as the thermoplastic resin (B). Select and combine those with relatively low melt viscosity.

When the same type of thermoplastic resins (A) and (B) are used, a system whose melt viscosity is reduced by the action of an additive (for example, a plasticizer) is called a thermoplastic resin (component) (B). It shall be.

The difference in melt viscosity between the two is preferably higher by 5 or more in MFR (melt flow rate) value in a flow test according to JIS K7210 (thermoplastic resin flow test method) at a temperature for press molding. It is set to 1000 poise or more in the flow test.

In the invention of claim 2, the thermoplastic resin (A) is selected from the above-mentioned thermoplastic resins excluding polyphenylene sulfide, polyphenylene oxide, polyether sulfone and polyether ether ketone. Give. As the cross-linking treatment, all of the cross-linking treatments which usually cross-link the polymer can be used. For example, crosslinking with an organic peroxide, crosslinking with an isocyanate, crosslinking with a silane compound, crosslinking with an amine and aziridine compound, crosslinking with a metal oxide, peroxide and sulfide, crosslinking with a metal halide and an organometallic halon compound, A photocrosslinking method, a crosslinking method using an electron beam and γ rays, or the like can be used.

The ratio of the thermoplastic resin to the reinforcing fiber is appropriately determined depending on the physical properties required for the fiber reinforced sheet, but the reinforcing fiber in the sheet is preferably 5 to 70% by weight. If the reinforcing fiber content is less than 5% by weight, the mechanical strength of the sheet will not be sufficient, and if it exceeds 70% by weight, it will be difficult to obtain a sheet uniformly impregnated with a thermoplastic resin.

As the net-like reinforcing material used in the invention of claim 3, any material may be used as long as it is made of a reinforcing fiber material and processed into a net-like face material by adhesion, weaving or the like.

In order to obtain the fiber reinforced sheet according to the third aspect of the present invention, a sheet corresponding to the fiber reinforced resin layer (a) (i) is manufactured in advance by the apparatus shown in FIG. 5 and the apparatus shown in FIG. The two may be laminated and integrated, and the powdery thermoplastic resin (A) is adhered and the powdery thermoplastic resin (B) is adhered on the continuous resin-adhered fiber bundle containing the net reinforcing material. The cut resin-attached fibers obtained by cutting the continuous resin-attached fiber bundle to a length of 5 mm or more may be dropped and accumulated, and then both may be heated and pressed to be laminated and integrated.

[0026]

The fiber reinforced sheet according to claims 1 to 3 comprises:
A fiber reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A), and a reinforcing fiber having a length of 5 mm or more is provided in a thermoplastic resin (B) in the longitudinal direction. Since the fiber-reinforced resin layer (i), which is randomly arranged, is laminated and integrated, this fiber-reinforced sheet can be machined in one direction due to the presence of the fiber-reinforced resin layer (a). It is suitable for molding a molded part that requires high mechanical strength, and the presence of the fiber reinforced resin layer improves the strength of the entire sheet.

In the invention of claim 1, the thermoplastic resin (A) has a larger melt viscosity than the thermoplastic resin (B),
In the invention of claim 2, the thermoplastic resin (A) is a crosslinked thermoplastic resin, and in the invention of claim 3, the fiber-reinforced resin layer (a) contains a net-like reinforcing material, so During heating during molding, the continuous reinforcing fibers arranged in one direction in the fiber-reinforced resin layer (a) do not flow unnecessarily.

According to a fourth aspect of the present invention, there is provided a method for producing a fiber-reinforced sheet according to the first aspect, in which a reinforcing fiber bundle composed of a large number of continuous monofilaments is arranged in upper, middle, and lower powdery thermoplastic resin flows. Passing through the layer and adhering the powdery thermoplastic resin to each filament of the fiber bundle, and the intermediate continuous resin-adhered fiber bundle to the gap between the upper and lower endless belts facing each other at a predetermined interval. Continuous feeding process, cutting the upper and lower resin-attached fiber bundles to 5mm or more, dropping the upper resin-attached fiber bundles onto the intermediate continuous resin-attached fiber bundles and accumulating them, and cutting the lower layer The resin-adhered fibers are dropped onto the feeding part into the gap between the upper and lower endless belts and accumulated, and both aggregates are continuously fed to the gap between the upper and lower endless belts along with the middle continuous resin-adhered fiber bundle. And a step of passing the upper and lower cut resin-attached fiber aggregates through a medium-sized continuous resin-attached fiber bundle with both endless belts to pass through the heating region and the cooling region to form a sheet. Therefore, the fiber composite sheet according to claim 1 can be continuously obtained.

Further, first, a reinforcing fiber bundle composed of a large number of continuous monofilaments is passed through a powdery thermoplastic resin fluidized bed arranged in upper, middle and lower layers, and a powder is applied to each filament of the fiber bundle. Since the thermoplastic resin is attached, the resin is sufficiently impregnated between the monofilaments of the reinforcing fibers in combination with the heating in the subsequent step.

Further, the upper and lower resin-attached fiber bundles are each cut into 5 mm or more, and the upper cut-resin-attached fiber bundles are dropped and accumulated on the intermediate continuous resin-attached fiber bundle, and the lower-cut resin-attached fiber bundles are collected. Since they are dropped and accumulated on the feeding part of the upper and lower endless belts into the gap, the reinforcing fibers are well dispersed in the fiber-reinforced resin layer (i) in units of monofilaments.

Further, the middle fluidized bed thermoplastic resin (A)
Since a resin having a higher melt viscosity than the thermoplastic resin (B) of the upper and lower fluidized beds is used for the above, as described above, when the obtained sheet is formed, the continuous reinforcing fibers aligned in one direction do not flow. .

[0032]

First, an apparatus used for producing the fiber-reinforced sheet of the invention of claim 4 will be described with reference to FIG. In the following description, the term “front” means the right direction in FIG. 1.

The fiber-reinforced sheet manufacturing apparatus shown in FIG.
Three upper, middle and lower fluidized bed units (1), a rewinding roll (2) placed behind each fluidized bed unit (1) and a front of each fluidized bed unit (1). A pair of upper and lower scrapers (3), a take-up drive roll (4) disposed diagonally below the upper scraper (3) and in front of the lower scraper (3), and a pair of take-up drive rolls (4). The pinch rolls (5) are arranged above the rotary cutters (6) facing each take-up drive roll (4) at predetermined intervals. The upper and lower endless belts (7) and (8), and the heating means (9) and cooling means (10) sequentially arranged from the rear side with respect to the opposed transfer parts (7a) and (8a) of the both endless belts (7) and (8) ) And, the lower endless belt
(8) The rear part of the upper endless belt (7) is made to project rearward, and the rearward extension of the transfer part (8a) is positioned below the upper and middle rotary cutters (6). It serves as a feeding portion (8b) into the gap between the belts (7) and (8). Instead of extending the transfer part (8a) to form the feeding part (8b), another endless belt may be arranged at the same place to provide the feeding part.

The tank bottom of the fluidized bed apparatus (1) is formed by a perforated plate (11), and the gas (G) such as air or nitrogen sent from the gas supply path is below the perforated plate (11). It is ejected upwards through a large number of holes. As a result, the powdery thermoplastic resin filled in the tank of the fluidized bed apparatus (1) is fluidized by the jetted gas (G) and is in the middle fluidized bed apparatus (1).
The fluidized bed (a) of the thermoplastic resin (A) is in the upper and lower fluidized bed units (1) of the thermoplastic resin (B) in the lower fluidized bed device (1).
Are formed respectively. Reinforcing fiber bundle (F1) is on the middle rewinding roll (2), and upper and lower rewinding rolls (2)
A reinforcing fiber bundle (f1) is wound around each. In addition,
Although only one reinforcing fiber bundle (F1) (f1) is shown for the sake of convenience, many reinforcing fiber bundles (F1) (f1) are actually used in parallel.

A guide roll (12) for guiding the fiber bundles (F1) (f1) is provided in the tank of each fluidized bed apparatus (1) and at the upper ends of the front and rear walls thereof. The medium-strength fiber bundle (F1) is passed through the fluidized bed (a) to form a resin-attached fiber bundle (F2), which is continuously continuous with the upper and lower endless belts (7) (8).
The guide roll (13) to guide the gap of the scraper
Guide rolls (14) are provided in front of (3) and above the feeding section (8b). The upper and lower reinforcing fiber bundles (f1) are also passed through the fluidized bed (b) to become resin-attached fiber bundles (f2).
Guide rollers (15) for guiding 2) to the rotary cutter (6) are provided in front of the scraper (3) respectively.

In this device, a pair of upper and lower scrapers (3) are arranged in order to adjust the amount of the powdery thermoplastic resin attached to the reinforcing fiber bundles (F1) (f1) so that the gap between them can be adjusted. However, vibration is applied to the reinforcing fiber bundle (F1) (f1),
Excessively adhered powdery thermoplastic resin may be removed.
In this case, the adhesion amount of the powdery thermoplastic resin can be adjusted depending on the strength of vibration applied.

The two endless belts (7) and (8) are continuously driven in the same direction by driving one of the upper and lower pulleys (16) and (17) respectively by a motor (not shown). It is designed to move at the same speed. The rear portion of the transfer portion (7a) of the upper endless belt (7) is inclined rearward and upward, and the gap between the vertical transfer portions (7a) and (8a) is widened rearward. The upper and lower endless belts (7) and (8) are formed of high strength and heat resistant materials such as steel, stainless steel, and glass cloth reinforced Teflon.

As the heating means (9), an electric heating type or hot air circulating type heating furnace is used, and the upper and lower endless belts (7) and (8) may be passed through them, or the upper and lower endless belts may be passed.
(7) A plurality of pairs of heating rolls may be used that press the transfer portions (7a) and (8a) of (7) and (8) from above and below and directly heat them. Heating means
Inside the (9) there are multiple pairs of upper and lower guide rolls (18), and at the corresponding positions of the upper and lower cooling means (10) there are multiple pairs of upper and lower guide rolls.
Rolls (19) are provided, and upper and lower guides
The gaps between the rolls (18) and (19) are adjustable. As the cooling means (10), there is used a blower for blowing air to cool the transfer parts (7a), (8a) of the upper and lower endless belts (7), (8). The guide roll (19) itself may be cooled.

Next, a method for producing the fiber reinforced sheet according to the invention of claim 1 using the above apparatus will be explained.

The reinforcing fiber bundle (F1) (f1) consisting of a large number of continuous monofilaments is wound from each rewinding roll (2) by a take-up drive roll (4) and a pinch roll (5) while preventing twisting. Then, the powdery thermoplastic resins (A) and (B) are passed through the fluidized beds (a) and (b). At this time, as the thermoplastic resin (A), one having a larger melt viscosity than the thermoplastic resin (B) is used. Reinforced fiber bundles in fluidized bed (a) (b)
(F1) and (f1) are separated and opened into monofilament units by the jetting of gas and the static electricity generated in the fluidized bed (a) and (b) and the rubbing and rubbing effect. Penetrates and adheres to the monofilament.

The resin-adhesion-reinforced fiber bundles (F2) (f2) are passed between a pair of upper and lower scrapers (3), and the scraper (3) removes excess powdery thermoplastic resin to obtain powdery thermoplastic resin. Adjust the ratio of resin and reinforcing fiber.

Then, a medium continuous resin-attached fiber bundle (F2)
Is continuously fed into the gap between the upper and lower endless belts (7) and (8),
On the other hand, the upper and lower resin-attached fiber bundles (f2) are each cut into 5 to 100 mm by a rotary cutter (6),
The upper cut resin-adhered fiber (f3) is dropped onto the middle continuous resin-adhered fiber bundle (F2) and accumulated, and the lower cut resin-adhered fiber (f3) is attached to the upper and lower endless belts (7) (8). The endless belts (7) and (8) are dropped and accumulated on the feeding part (8b) into the gap, and both are moved along with the middle continuous resin-attached fiber bundle (F2).
Continuously feed into the gap. Medium continuous resin-attached fiber bundle
Upper and lower cut resin-attached fiber aggregates (f
4) While moving through the two endless belts (7) and (8), set the minimum gap between the two endless belts (7) and (8) to the upper and lower guide rolls (18).
Then, the three are pressurized in the thickness direction and passed through a heating furnace (9) as a heating means in which hot air circulates to be integrated. The temperature at this time is equal to or higher than the melting temperature of the thermoplastic resin (B).

Subsequently, the mixture of the resin and the reinforcing fiber in the molten state is adjusted by the upper and lower endless belts (7) and (8) by the upper and lower guide rolls (19) to pressurize the mixture, and as a cooling means. The fiber-reinforced sheet (S1) was obtained by cooling with the cooling blower (10).

The fiber reinforced sheet (S1) thus obtained was prepared by continuously adding the thermoplastic resin (A) to the continuous reinforced fiber as shown in FIG.
Through the fiber-reinforced resin layer (a) in which (F3) is aligned in one direction, the thermoplastic resin (B) has a length of 5 to 5 mm.
Two fiber-reinforced resin layers (i) in which 100 mm reinforcing fibers (f5) are randomly arranged in the longitudinal direction are laminated and integrated in a sandwich form.

Next, examples of the inventions of claims 1 and 4 will be shown.

Example 1 As the thermoplastic resin (A), 100 parts by weight of a vinyl chloride resin having a degree of polymerization of 800 (average particle size 150 μm) was mixed with 3 parts by weight of butyltin maleate and 5 parts by weight of a glycidyl methacrylate copolymer. (Measured using a Koka type flow tester. Melt viscosity at press-moldable temperature: 6000 poise). Thermoplastic resin (B)
As the material, 100 parts by weight of a vinyl chloride resin having a degree of polymerization of 400 and 3 parts by weight of butyltin maleate and 5 parts by weight of a glycidyl methacrylate copolymer were used (melt viscosity under the same conditions as A: 850 poise).

In FIG. 1, as the reinforcing fiber bundles (F1) and (f1), roving glass fiber bundles (monofilament diameter 14 μm, 1100 g / km) were used.

The upper and lower endless belts (7) and (8) have a width of 600 mm,
A glass fiber reinforced Teflon belt having a thickness of 1 mm was used.

The medium-strength fiber bundle (F1) is continuously passed through the fluidized bed (a) of the powdery thermoplastic resin (A), and the powdery thermoplastic resin (A) is placed between the monofilaments. Was impregnated and attached to each monofilament, the excess was removed by a scraper (3), and the weight ratio of the resin and the reinforcing fiber was adjusted to 1: 1. At this time, the reinforcing fiber bundle (F2) after adjusting the resin adhesion amount is 1970 g
/ M ² . The continuous resin-attached fiber bundle (F2) is guided by guide rolls (13) (14) to the upper and lower endless belts (7) (8).
Continuously feed into the gap.

The upper and lower reinforcing fiber bundles (f1) are continuously passed through the fluidized bed (b) of the powdery thermoplastic resin (B),
After the powdery thermoplastic resin (B) is impregnated between the monofilaments and attached to each monofilament, the excess is removed by the scraper (3), and the weight ratio of the resin and the reinforcing fiber becomes 8: 2. Was adjusted.
The reinforced fiber bundle (f2) after adjusting the resin adhesion amount is cut into 25 mm each by the rotary cutter (6), and the upper cut resin adhesion fiber (f3) is dropped onto the middle continuous resin adhesion fiber bundle (F2). And collect them, and the lower cut resin-attached fibers (f
3) is dropped and accumulated on the feeding portion (8b) into the gap between the upper and lower endless belts (7) and (8).

Medium continuous resin-attached fiber bundle (F2) and feeding
The width of the groove (8b) is 600mm, and the upper part of these widths
And lower cut resin-attached fibers (f3) are 1740 g each
/ M ²It fell and accumulated so that. Both cutting trees at this time
The apparent thickness of the fat-attached fiber aggregate (f4) is about 11 each.
It was mm.

The aggregate (f4) of both is continuously fed into the gap between the upper and lower endless belts (7) and (8) together with the movement of the intermediate continuous resin-attached fiber bundle (F2), and the intermediate continuous resin-attached fiber bundle Through the (F2), the upper and middle cut resin-attached fiber aggregates (f4)
While sandwiching between the two endless belts (7) (8) that move at 0 mm / min,
It was passed through a 1500 mm long hot air heating furnace (9) in which hot air of about 200 ° C. was circulated. This guide roll (1
Adjust the gap between the upper and lower endless belts (7) and (8) to 3.1 mm with 8) and pressurize, and then use the guide roll (19) to reduce the gap between the upper and lower endless belts (7) and (8) to 3 mm. It is cooled by a cooling blower (10) while being adjusted to and pressurized.

In this way, the continuous reinforcing fibers (F3) as shown in FIG. 2 are arranged in one direction and are arranged in one direction. Reinforcement fibers (f5) are arranged in random directions 1 each
mm-thick fiber reinforced resin layer (i) is laminated, width 600 mm,
A fiber reinforced sheet (S1) having a thickness of 3 mm was obtained.

Example 2 A fiber reinforced sheet having the same structure as in Example 1 was obtained in the same manner as in Example 1 except for the following.

As the thermoplastic resin (A), nylon 6 is used.
6 is used, and the thermoplastic resin (B) is nylon 12
Was used.

As the reinforcing fiber bundle (F1), a roving glass fiber bundle (monofilament diameter 14 μm, 110
0 g / km), using a thermoplastic resin (A) and a reinforcing fiber bundle (F
The weight ratio of 1) is 1: 1 and the reinforcing fiber bundle (f1) is
The same as the reinforcing fiber bundle (F1), the thermoplastic resin (B)
And the reinforcing fiber (f1) weight ratio is 8: 2 and the cutting length is 25
mm.

Example 3 A fiber reinforced resin layer (A) was prepared in the same manner as in Example 1 except for the following.
Thickness of 1mm, each thickness of both fiber reinforced resin layers (i) 1.5m
A fiber-reinforced sheet having a length of 50 mm and a length of the reinforcing fiber (f5) of the fiber-reinforced resin layer (i) having an overall thickness of 4 mm and a thickness of 4 mm was obtained.

The thermoplastic resin (A) has a degree of polymerization of 54
A mixture of 3 parts by weight of butyltin maleate and 5 parts by weight of glycidyl methacrylate copolymer (100 parts by weight of vinyl chloride resin of 0) (melt viscosity 2000 poise) was used, and the thermoplastic resin (B) had a degree of polymerization of 540. Dioctyl phthalate (plasticizer DO
P) 5 parts by weight, butyltin maleate 3 parts by weight and glycidyl methacrylate copolymer 5 parts by weight (melt viscosity 1050 poise) were used.

As the reinforcing fiber bundle (F1), a roving glass fiber bundle (monofilament diameter 23 μm, 440
0 g / km), using a thermoplastic resin (A) and a reinforcing fiber bundle (F
The weight ratio of 1) is 1: 1 and the reinforcing fiber bundle (f1) is
The same as the reinforcing fiber bundle (F1), the thermoplastic resin (B)
And the reinforcing fiber (f1) weight ratio is 3: 1 and the cutting length is 50
mm.

Example 4 A fiber reinforced resin layer (a) was prepared in the same manner as in Example 1 except for the following.
Thickness of 1mm, each thickness of both fiber reinforced resin layers (i) 1.5m
A fiber-reinforced sheet having a total thickness of 4 mm and a length of the reinforcing fiber (f5) of the fiber-reinforced resin layer (1) of 12.5 mm was obtained.

Polyethylene terephthalate was used as the thermoplastic resin (A), and polybutylene terephthalate was used as the thermoplastic resin (B).

As the reinforcing fiber bundle (F1), a roving polyacrylonitrile-based carbon fiber bundle in which 6000 monofilaments having a diameter of 7 μm are bundled is used, and the weight ratio of the thermoplastic resin (B) to the reinforcing fiber bundle (F1) is used. Was set to 1: 1.

As the reinforcing fiber bundle (f1), the reinforcing fiber bundle (F1)
Using the same as above, thermoplastic resin (B) and reinforcing fiber (f1)
Was 3: 1 and the cut length was 12.5 mm.

Example 5 A fiber reinforced sheet having the same structure as in Example 1 was obtained in the same manner as in Example 1 except for the following.

Polypropylene is used as the thermoplastic resin (A) (melt viscosity according to JIS K7210: MF
An R value of 0.5) and high density polyethylene was used as the thermoplastic resin (B) (MFR value of 30).

Comparative Example 1 Example except that 100 parts by weight of vinyl chloride resin having a polymerization degree of 540, 3 parts by weight of butyltin maleate and 5 parts by weight of glycidyl methacrylate copolymer were used as the thermoplastic resin (B). A fiber reinforced resin sheet was obtained in the same manner as in 1.

Comparative Example 2 A fiber reinforced resin sheet was obtained in the same manner as in Example 2 except that nylon 12 was used as the thermoplastic resin (A).

Comparative Example 3 As a thermoplastic resin (B), 100 parts by weight of a vinyl chloride resin having a polymerization degree of 540 was mixed with 3 parts by weight of butyltin maleate, 5 parts by weight of a glycidyl methacrylate copolymer and 5 parts by weight of dioctyl phthalate. A fiber-reinforced resin sheet was obtained in the same manner as in Example 3 except that it was used.

Comparative Example 4 A fiber reinforced resin sheet was obtained in the same manner as in Example 4 except that polybutylene terephthalate was used as the thermoplastic resin (A).

Comparative Example 5 A fiber reinforced resin sheet was obtained in the same manner as in Example 5 except that polypolypropylene was used as the thermoplastic resin (B).

Press Molding of Fiber Reinforced Resin Sheet The sheets of Examples 1-5 and Comparative Examples 1-5 are aligned in one direction and have a side parallel to the direction of the reinforcing fibers 425 × 4.
Cut out into a 25 mm square and heat in a far infrared heating furnace,
It was placed in the center of a 600 × 600 mm square flat plate mold and press-molded. From the positions (I) to (V) shown in FIG. 3 of the molded flat plate, a test piece having a width of 20 mm and a length of 150 mm was arranged in parallel with the direction of the reinforcing fibers aligned in the direction indicated by the arrow (y) in the length direction. And cut out 5 pieces, JIS K
Based on 7203, the results of measuring the flexural modulus (kg / mm ² ) by performing a 3-point bending test with a fulcrum distance of 120 mm and the thickness of the flat plate after forming are shown in Table 1.

[0072]

[Table 1]

Example 6 and Comparative Example 6 The sheets of Example 1 and Comparative Example 1 were molded into an inverted U-shaped member (M) shown in FIG.

When the sheet was placed on the mold, the longitudinal direction of the inverted U-shaped member and the fibers aligned in one direction were made parallel to each other. From a random position on the top wall of the molded inverted U-shaped member, five test pieces with a width of 20 mm and a length of 150 mm were cut out in parallel with the longitudinal direction of the inverted U-shaped member, and JIS K720 was used.
Table 2 shows the results of measuring the bending elastic modulus (kg / mm2) by conducting a three-point bending test at a distance between fulcrums of 120 mm in accordance with 3.

[0075]

[Table 2]

Next, an embodiment of the invention of claim 2 will be shown.

Example 7 In the invention of claim 1, the thermoplastic resin (A) having a larger melt viscosity than the thermoplastic resin (B) is used.
The invention of claim 2 is different from that of Example 1 in the same manner as in Example 1 except that the thermoplastic resin (A) is cross-linked as described below. A fiber reinforced sheet having the same structure as in Example 1 was manufactured.

As the thermoplastic resin (A), polyvinyl chloride (PVC) which was cross-linked at 160 ° C. with the following composition was used.

[0079] PVC 100 parts by weight Dioctyl phthalate 3〃 Dibutyltin dilaurate 5 〃 Magnesium oxide 8〃 Dicumyl peroxide 2.4〃 Triallyl isocyanurate 5 〃 PVC was used as the thermoplastic resin (B).

Example 8 A fiber reinforced sheet having the same structure as in Example 1 was obtained in the same manner as in Example 1 except for the following.

The reinforcing fiber bundle (F1) is impregnated with the resin by extruding and laminating the resin having the following composition, and by laminating the same crosslinked thermoplastic resin film on the upper and lower sides, the fiber reinforced resin layer ( Ah) formed.

High-density polyethylene 100 parts by weight α · α-bis (t-butylperoxyisopropyl) benzene 1.69 〃 High-density polyethylene was used as the thermoplastic resin (B).

Further, the thermoplastic resin (A) and the reinforcing fiber bundle (F1)
Was set to 4: 6, and the weight ratio of the thermoplastic resin (B) to the reinforcing fiber bundle (f1) was set to 8: 2.

Example 9 A fiber reinforced resin layer (A) was prepared in the same manner as in Example 1 except for the following.
Thickness of 1mm, each thickness of both fiber reinforced resin layers (i) 1.5m
A fiber-reinforced sheet having a length of 50 mm and a length of the reinforcing fiber (f5) of the fiber-reinforced resin layer (i) having an overall thickness of 4 mm and a thickness of 4 mm was obtained.

As the thermoplastic resin (A), the above EVA can be used.
A PVC graft copolymer obtained by crosslinking treatment at 160 ° C. with the following composition was used.

EVA-PVC 100 parts by weight Dioctyl phthalate 3 〃 Dibutyltin dilaurate 5 〃 Magnesium oxide 8 〃 Dicumyl peroxide 2.4 〃 Triallyl isocyanurate 5 〃 As thermoplastic resin (B), EVA-PVC graft copolymer Coalescence was used.

As the reinforcing fiber bundle (F1), a roving polyacrylonitrile-based carbon fiber bundle in which 6000 monofilaments having a diameter of 7 μm are bundled is used, and the weight ratio of the thermoplastic resin (A) to the reinforcing fiber bundle (F1) is used. Is 4: 6,
As the reinforcing fiber bundle (f1), a roving glass fiber bundle (monofilament diameter 23 μm, 4400 g / km)
Was used, the weight ratio of the thermoplastic resin (B) to the reinforcing fiber bundle (f1) was 7: 3, and the cut length was 25 mm.

Example 10 A fiber reinforced sheet having the same structure as in Example 1 was obtained in the same manner as in Example 1 except for the following.

The reinforcing resin bundle (F1) is impregnated with the thermoplastic resin (A) by extruding and laminating a resin having the following composition, and laminating the same crosslinked thermoplastic resin film on the upper and lower sides. A fiber reinforced resin layer (a) was formed.

EVA 100 parts by weight dicumyl peroxide (40%) 2 〃 stearic acid 1 〃 As the thermoplastic resin (B), an ethylene-vinyl acetate copolymer (EVA; VA content 15%) was used.

As the reinforcing fiber bundle (F1), roving is used.
Glass fiber bundles (monofilament diameter 23 μm, 4
400 g / km) using thermoplastic resin (A) and reinforcing fiber
The weight ratio of the bundle (F1) is set to 1: 1 (the resin impregnation strength at this time is
Chemical fiber bundle is 1740 g / m ²), The reinforcing fiber bundle (f1)
For roving glass fiber bundles (of monofilament
Thermoplastic resin with a diameter of 14 μm, 1100 g / km)
The weight ratio of (B) and the reinforcing fiber bundle (f1) is set to 7: 3 and cut.
The length was 25 mm.

Example 11 A fiber reinforced resin layer (A) was prepared in the same manner as in Example 1 except for the following.
Thickness of 1mm, each thickness of both fiber reinforced resin layers (i) 1.5m
A fiber-reinforced sheet having a length of 50 mm and a length of the reinforcing fiber (f5) of the fiber-reinforced resin layer (i) having an overall thickness of 4 mm and a thickness of 4 mm was obtained.

The same crosslinked polyvinyl chloride as in Example 7 was used as the thermoplastic resin (A), and ethylene-vinyl chloride was used as the thermoplastic resin (B).

As the reinforcing fiber bundle (F1), a roving glass fiber bundle (monofilament diameter 14 μm, 110
0 g / km), thermoplastic resin (A) and reinforcing fiber bundle (F1)
Of the roving-shaped glass fiber bundle (monofilament diameter 14
μm, 1100 g / km), the weight ratio of the thermoplastic resin (B) to the reinforcing fiber bundle (f1) is 8: 2, and the cutting length is 50
mm.

Comparative Example 7 A fiber reinforced sheet was obtained in the same manner as in Example 7 except that the same polyvinyl chloride as the thermoplastic resin (B) was used as the thermoplastic resin (A).

Comparative Example 8 A fiber reinforced sheet was obtained in the same manner as in Example 8 except that the same high-density polyethylene as the thermoplastic resin (B) was used as the thermoplastic resin (A).

Comparative Example 9 As the thermoplastic resin (A), the same E as the thermoplastic resin (B) was used.
Example 9 except that a VA-PVC graft copolymer was used
A fiber reinforced sheet was obtained in the same manner as.

Comparative Example 10 A fiber reinforced sheet was obtained in the same manner as in Example 10 except that the same ethylene-vinyl acetate copolymer as the thermoplastic resin (B) was used as the thermoplastic resin (A).

For Examples 7 to 11 and Comparative Examples 7 to 10, the thickness of the flat plate after molding, and Examples 1 to 5 and Comparative Example 1
Bending elastic modulus (kg / m
Table 3 shows the measurement results of m ² ).

[0100]

[Table 3]

Example 12 and Comparative Example 11 The sheets of Example 7 and Comparative Example 7 were molded into an inverted U-shaped member shown in FIG. 4 and tested in the same manner as in Example 6 and Comparative Example 6 to find the flexural modulus. Table 4 shows the results of measuring (kg / mm ² ).

[0102]

[Table 4]

Finally, an embodiment of the invention of claim 3 will be described.

First, the apparatus used for producing the fiber reinforced sheet of the invention of claim 3 and the method for producing the sheet will be described with reference to FIG.
And FIG. 6 will be described. In the following description, the term “front” refers to the right direction in FIGS. 5 and 6.

FIG. 5 shows an apparatus for producing a sheet (a) for a medium fiber reinforced resin layer (a) of a fiber reinforced sheet, which is similar to the medium fluidized bed apparatus (1) shown in FIG. Are arranged vertically, a rewinding roll (20) of a long net-like reinforcing material (N) is arranged in front of the middle, and further three heating rolls (21) and two pairs of upper and lower cooling rolls (22) are arranged in front of them. ) And a pair of upper and lower pinch rolls (23) are sequentially arranged.

FIG. 6 shows an apparatus for producing the sheet (a) for the fiber reinforced resin layer (i) in the fiber reinforced sheet, and the continuous adhered fiber bundle (F2) is made up and down in all the apparatuses shown in FIG. Excluding the device for leading to the endless belts (7), (8) and the device for forming the upper cut resin-attached fiber bundle (f1), the cooling blower (10) and the guide roll ( A cooling guide roll (24) is provided instead of 19).

5 and 6, the same elements as those in FIG. 1 are designated by the same reference numerals and the description thereof will be omitted.

In FIG. 5, the net-like reinforcing material (N) is rewound from the rewinding roll (20) by driving the pinch roll (23), and the upper and lower continuous resin-attached fiber bundles (F)
By sandwiching it between 2), heating and pressurizing with a heating roll (21) to integrate them, and then cooling while applying pressure with a cooling roll (22), continuous reinforcing fibers are added to the thermoplastic resin (A). A fiber reinforced resin sheet (a) having a net-shaped reinforcing material (N) incorporated therein was obtained in a state of being aligned in one direction.

Further, in FIG. 6, the cut resin-attached fiber (f3)
Are dropped onto the feeding part (8b) into the gap between the upper and lower endless belts (7) and (8) and accumulated, and the cut resin-adhered fiber aggregate (f4) is moved by the two endless belts (7) and (8). While watching, both endless belts
The minimum gap between (7) and (8) is adjusted by the upper and lower guide rolls (18), and pressure is applied in the thickness direction to pass through the heating furnace (9) in which hot air is circulated.

Subsequently, the minimum gap between the upper and lower endless belts (7) and (8) is adjusted by the upper and lower cooling guide rolls (24) to pressurize the mixture of the molten resin and the reinforcing fibers, while applying the cooling guide. It was cooled by a roll (24) to obtain a fiber reinforced resin sheet (a) in which reinforcing fibers having a length of 5 to 100 mm were arranged in a random state in the length direction in the thermoplastic resin (B).

Then, one fiber-reinforced resin sheet (a)
And two fiber reinforced resin sheets (a) are cut into a predetermined size, heated by far infrared rays, respectively, and then placed in the central portion of a square flat plate-shaped die, and the fiber reinforced resin sheet (a) , The fiber-reinforced resin sheet (a) and the fiber-reinforced resin sheet (a) are stacked and pressed in this order,
Continuous reinforcing fiber (F)
The length of the fiber reinforced resin layer (a), in which 3) is aligned in one direction, and the thermoplastic resin (B) are 5 to 100
mm reinforcing fibers (f5) are laminated and integrated with a fiber reinforced resin layer (i) in which the fiber is reinforced in a random manner in the longitudinal direction. ) Was obtained to obtain a fiber reinforced sheet (S2).

Next, an embodiment of the invention of claim 3 will be shown.

Example 13 Polypropylene was used as the thermoplastic resins (A) and (B).

As the reinforcing fiber bundle (F1), a roving glass fiber bundle (monofilament diameter 14 μm, 110
0 g / km), using a thermoplastic resin (A) and a reinforcing fiber bundle (F
The weight ratio of 1) is 1: 1 and the reinforcing fiber bundle (f1) is
The same as the reinforcing fiber bundle (F1), the thermoplastic resin (B)
And the reinforcing fiber bundle (f1) weight ratio is 6: 4, and the cutting length is 2
It was set to 5 mm.

The net-like reinforcing material (N) is glass fiber, thickness 0.13 mm, mesh 3 × 3 / cm, weight 4
The one with 0 g / m ² was used.

A sheet (a) having a thickness of 1 mm was manufactured by the apparatus shown in FIG. 5, and a sheet (a) having a thickness of 1 mm was manufactured by the apparatus shown in FIG.

425 from each of the sheets (A) and (B)
Cut out 1 x 425 mm square sheet, 2 x 2 sheets, and heat each with far infrared rays, then stack 3 sheets in the order of sheet (a), sheet (a) and sheet (a), 600 x 600 mm square Placed in the center of the flat plate mold and press-molded, the fiber reinforced resin layer (a) in which continuous reinforcing fibers (F3) are arranged in one direction in the thermoplastic resin (A) , Thermoplastic resin (B) with a length of 25 mm
The fiber-reinforced resin layer (i) in which the reinforcing fibers (f1) of (1) are randomly arranged in the longitudinal direction are laminated and integrated,
A fiber-reinforced sheet having a thickness of 1.5 mm in which the net-shaped reinforcing material (N) was incorporated in the fiber-reinforced resin layer (a) was obtained.

Example 14 A fiber reinforced sheet having the same structure as in Example 13 was obtained in the same manner as in Example 13 except for the following.

As the thermoplastic resins (A) and (B), 100 parts by weight of vinyl chloride resin having a degree of polymerization of 600, 3 parts by weight of butyltin maleate and 5 parts of glycidyl methacrylate copolymer are used.
A mixture of 5 parts by weight and 5 parts by weight of dioctyl phthalate was used.

The weight ratio of the thermoplastic resin (A) to the reinforcing fiber bundle (F1) was 4: 6, and the reinforcing fiber bundle (f1) was a roving glass fiber bundle (monofilament diameter 23 μm).
m, 4400 g / km) and the weight ratio of the thermoplastic resin (B) to the reinforcing fiber bundle (f1) was 7: 3.

Example 15 A fiber reinforced sheet having the same structure as in Example 13 was obtained in the same manner as in Example 13 except for the following.

Polybutylene terephthalate was used as the thermoplastic resins (A) and (B). As the reinforcing fiber bundle (F1), a roving polyacrylonitrile-based carbon fiber bundle in which 6000 monofilaments having a diameter of 7 μm are bundled is used, and the weight ratio of the thermoplastic resin (A) to the reinforcing fiber bundle (F1) is 6: 4, the same reinforcing fiber bundle (f1) as in Example 1 was used, and the thermoplastic resin (B) and the reinforcing fiber bundle were used.
The weight ratio of (f1) was 3: 1 and the cutting length was 50 mm.

As the net-like reinforcing material (N), glass fiber, thickness 0.26 mm, mesh 2 × 2 / cm, weight 8
The one having 5 g / m ² was used.

The thickness of the sheet (a) was 1.5 mm, and the thickness of the fiber reinforced sheet after press molding was 2 mm.

Example 16 A fiber reinforced sheet having the same structure as in Example 13 was obtained in the same manner as in Example 13 except for the following.

Nylon 66 was used as the thermoplastic resins (A) and (B).

As the reinforcing fiber bundle (F1), a roving-like polyacrylonitrile-based carbon fiber bundle in which 6000 monofilaments having a diameter of 7 μm are bundled is used, and the weight ratio of the thermoplastic resin (A) to the reinforcing fiber bundle (F1) is used. 1: 1 and
As the reinforcing fiber bundle (f1), a roving glass fiber bundle (monofilament diameter 23 μm, 4400 g / km)
Was used, and the weight ratio of the thermoplastic resin (B) and the reinforcing fiber bundle (f1) was set to 3: 1.

The net-like reinforcing material (N) is glass fiber, thickness 0.17 mm, mesh 4 × 4 / cm, weight 5
The one having 5 g / m ² was used.

The thickness of the sheet (a) was 3 mm, and the thickness of the fiber reinforced sheet after press molding was 2 mm.

Example 17 A fiber reinforced sheet having the same structure as in Example 13 was obtained in the same manner as in Example 13 except for the following.

As the thermoplastic resins (A) and (B), 100 parts by weight of a vinyl chloride resin having a polymerization degree of 400 and 3 parts by weight of butyltin maleate and 5 parts by weight of a glycidyl methacrylate copolymer were used.

As the reinforcing fiber bundle (F1), a roving glass fiber bundle (monofilament diameter 14 μm, 1
100 g / km), the weight ratio of the thermoplastic resin (A) to the reinforcing fiber bundle (F1) is 4: 6, and the same reinforcing fiber bundle (f1) as in Example 13 is used. (B)
And the reinforcing fiber bundle (f1) weight ratio is 7: 3, and the cutting length is 1
It was set to 2.5 mm.

The net-like reinforcing material is glass fiber,
Thickness 0.1mm, mesh 2 × 2 / cm, weight 29g / m
The one used was ² .

The thickness of the sheet (a) was 3 mm, and the thickness of the fiber reinforced sheet after press molding was 2 mm.

Comparative Examples 12 to 16 Comparative Examples 12 to 16 are the same as Examples 13 to 17 except that the net reinforcing material (N) is removed, but the thickness is the same for both the former and the latter.

Tests were carried out for Examples 13 to 17 and Comparative Examples 12 to 16 in the same manner as in Examples 1 to 5 and Comparative Examples 1 to 5, and the bending elastic modulus (kg / mm ² ) was measured. 5 shows.

[0137]

[Table 5]

Example 18 and Comparative Example 17 The sheets of Example 13 and Comparative Example 12 were molded into an inverted U-shaped member (M) shown in FIG. 4 and tested in the same manner as in Example 6 and Comparative Example 6, The results of measuring the flexural modulus (kg / mm ² ) are shown in Table 6.

[0139]

[Table 6]

[0140]

According to the fiber reinforced sheet of the inventions of claims 1 to 3, due to the presence of the fiber reinforced resin layer (a), it is suitable for molding a molded part which requires mechanical strength in one direction,
Further, the presence of the fiber reinforced resin layer (2) improves the strength of the entire sheet, and is therefore excellent as a press-molding sheet.

Further, since the continuous reinforcing fibers arranged in one direction in the fiber-reinforced resin layer (a) do not flow unnecessarily at the time of heating in press molding, they do not flow unnecessarily. Molding with the sheet according to the invention makes it possible to obtain moldings which are reinforced sufficiently and uniformly in the desired direction.

Further, according to the method for producing a fiber-reinforced sheet of the invention of claim 4, the fiber-reinforced sheet of claim 1 can be continuously obtained, so that the productivity is good.

The resin is sufficiently impregnated between the monofilaments of the reinforcing fibers, and the reinforcing fibers are well dispersed in the fiber-reinforced resin layer (i) in units of monofilaments, so that the reinforcing effect of the reinforcing fibers is great. The obtained sheet shows excellent physical properties.

Further, since the distribution of the reinforcing fiber and the resin becomes uniform, a fiber-reinforced sheet having uniform physical properties can be obtained.

Moreover, when the sheet obtained by the method of the present invention is used for molding, continuous reinforcing fibers aligned in one direction do not flow, so that a molded product sufficiently and uniformly reinforced in a desired direction can be obtained. You can

[Brief description of drawings]

FIG. 1 is a side view showing a state in which a sheet according to the invention of claims 1 and 2 is manufactured by a fiber-reinforced sheet manufacturing apparatus.

FIG. 2 is a partial plan view of the sheet in which an upper fiber-reinforced resin layer (II), an intermediate fiber-reinforced resin layer (II) and a lower fiber-reinforced resin layer (II) are sequentially cut away.

FIG. 3 is an explanatory view of cutting out a test piece from a fiber reinforced sheet.

FIG. 4 is a perspective view of an inverted U-shaped member molded using the fiber reinforced sheet obtained by the invention of claims 1 to 3.

FIG. 5 is a side view showing a production state of a fiber-reinforced resin layer (a) sheet in a fiber-reinforced sheet according to the invention of claim 3.

FIG. 6 is a side view showing a production state of a sheet for fiber-reinforced resin layer (II) in the fiber-reinforced sheet according to the invention of claim 3.

FIG. 7 is a partial plan view of a sheet in which each layer in the fiber-reinforced sheet of the invention of claim 3 is sequentially cut away.

[Explanation of symbols]

(A) (B) Thermoplastic resin (A) (I) Fiber reinforced resin layer (F3) Continuous reinforcing fiber (f5) Reinforcing fiber (N) Net-shaped reinforcement (F1) (f1) Reinforced fiber bundle (a) (b) Fluidized bed (F2) Continuous resin-attached fiber bundle (f2) Resin-attached fiber bundle (f3) Cut resin-attached fiber (f4) Cut resin-attached fiber aggregate (7) Upper endless belt (8) Lower endless belt

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display location // B29K 105: 06

Claims (4)

[Claims] 1. A fiber reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A), and a thermoplastic resin (B) is reinforced with a length of 5 mm or more. The thermoplastic resin (A) has a larger melt viscosity than the thermoplastic resin (B) because it is laminated and integrated with the fiber-reinforced resin layer (i) in which the fibers are randomly arranged in the longitudinal direction. Fiber reinforced sheet. 2. A fiber-reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A), and a thermoplastic resin (B) is reinforced with a length of 5 mm or more. A fiber reinforced sheet which is a thermoplastic resin obtained by laminating and integrating a fiber reinforced resin layer (i) in which fibers are arranged in a random state in the longitudinal direction, and a thermoplastic resin (A) is cross-linked. 3. A fiber reinforced resin layer (a) in which continuous reinforcing fibers are arranged in one direction in a thermoplastic resin (A), and a thermoplastic resin (B) is reinforced with a length of 5 mm or more. A fiber reinforced sheet in which fibers and a fiber reinforced resin layer (i) in which the fibers are arranged in a random state in the longitudinal direction are laminated and integrated, and a net-shaped reinforcing material is incorporated in the fiber reinforced resin layer (a). . 4. A) a reinforcing fiber bundle composed of a large number of continuous monofilaments is passed through a powdery thermoplastic resin fluidized bed arranged in upper, middle and lower layers, and each filament of each fiber bundle is powdered. A step of adhering a body-like thermoplastic resin, b) a step of continuously feeding a medium-sized continuous resin-adhered fiber bundle into gaps between upper and lower endless belts opposed to each other at a predetermined interval, and c) upper and lower layers Each of the resin-attached fiber bundles is cut into 5 mm or more, the upper cut resin-attached fibers are dropped onto the middle continuous resin-attached fiber bundle and accumulated, and the lower cut resin-attached fibers are placed in the gap between the upper and lower endless belts. Of the intermediate continuous resin-adhered fiber bundles, which are dropped and accumulated on the feeding part of the belt, and are continuously fed into the gap between the upper and lower endless belts as the intermediate continuous resin-adhered fiber bundles move. To Then, the upper and middle cut resin-attached fiber aggregates are sandwiched by both moving endless belts and passed through a heating region and a cooling region to form a sheet. The method for producing a fiber-reinforced sheet according to claim 1, wherein a resin (A) having a higher melt viscosity than the thermoplastic resin (B) of the upper and lower fluidized beds is used.