JPH07243148A - Molding material for fiber-reinforced thermoplastic resin molding and method for producing the same - Google Patents

Abstract

PURPOSE:To provide the molding material capable of not only easily molding FRTP having complicated curved surfaces but also molding FRTP excellent in mechanical characteristics, and to provide a method for producing the same. CONSTITUTION:A molding material for fiber-reinforced thermoplastic resin moldings comprises woven fabric using the laminates of reinforcing multifilament yarns 2 and thermoplastic multifilament yarns 3 or slit yarns as weaving yarns, and to provide a method for producing the same.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a material for molding a fiber reinforced thermoplastic resin (hereinafter referred to as FRTP) and a method for producing the material. INDUSTRIAL APPLICABILITY The present invention is particularly useful when applied to the molding of FRTP having a complicated shape.

[0002]

2. Description of the Related Art As a material for molding FRTP, for example, carbon fiber reinforced thermoplastic resin (hereinafter referred to as CFRTP), thermoplastic fiber yarns such as nylon fiber, polyester fiber, polypropylene fiber and carbon fiber yarn have been conventionally used. Mixed woven fabrics are known. Such a molding material melts only the thermoplastic fiber yarn by heating during molding to form a matrix of nylon, polyester, polypropylene or the like. With such a molding method, the shear deformation of the woven fabric can be utilized as it is, and thus there is an advantage that the shape of the final product can be formed simultaneously with the resin impregnation during molding.

However, such conventional molding materials have the following problems. Tokkyo 1-35
As proposed in Japanese Patent No. 101, a carbon fiber yarn and a thermoplastic multifilament yarn or a slit yarn (hereinafter, also simply referred to as a thermoplastic fiber yarn) are aligned in a warp yarn and a weft yarn. Since the fibrous yarn and the thermoplastic fiber yarn are completely independent and parallel to each other, even if the thermoplastic fiber yarn is melted and impregnated between the carbon fiber yarns by heating at the time of molding, the spreadability of the carbon fiber yarns is reduced. There is a problem that the impregnation is not uniform, and even if an attempt is made to pressurize by heating and then forcibly impregnating the carbon fiber yarn, the carbon fiber threads act as spacers, resulting in nonuniform pressurization and sufficient impregnation cannot be expected.

With respect to the spreadability of carbon fiber yarns, in the case of ordinary woven yarns of carbon fiber woven fabrics, the cross-sections of the woven yarns are aggregated into an elliptical shape due to the interlacing of the woven yarns, and twists are imparted to the woven yarns. However, even if it is untwisted, it is often difficult to sufficiently impregnate the resin because the individual fibers are entangled. In particular, when each single fiber of each woven yarn is firmly adhered with a sizing agent, it becomes worse, and there is a problem that high resin impregnation property cannot be expected.

Under these circumstances, it has recently been attempted to make a woven fabric by using a mixed yarn (commingle yarn) in which carbon fibers and thermoplastic fibers are uniformly mixed. When such a method is adopted, since the carbon fibers and the thermoplastic fibers are uniformly dispersed in the woven fabric substrate, a high impregnation property of the matrix resin can be obtained.

However, in this method, even if the carbon fiber and the thermoplastic fiber are uniformly dispersed by air entanglement or the like, the carbon fiber having extremely low elongation takes the tension due to the tension in the actual weaving process. That is, since it is stretched straight, the entanglement can be easily released. Then, each of them becomes independent, which is the same as so-called alignment. In addition, there is a problem that it is necessary to mix the fibers in advance and the manufacturing cost is high.

Further, as a problem in the prior art of aligning the thermoplastic fiber yarn and the carbon fiber yarn, the base carbon fiber woven fabric is to obtain a fiber reinforced resin having high handleability and a high carbon fiber content. In addition, a tight weaving structure with a narrow weaving yarn interval is used. Then, the shear deformability of the woven fabric naturally has a limit, and there is a problem that it cannot be formed on a large curved surface.

In order to enhance the shear deformability, there are measures such as increasing the interval between weaving yarns or adopting a satin weave design with a reduced number of cross points in the weave design. However, in the former case, since the resin is unevenly distributed in the gaps of the weaving yarn because it is an open woven fabric, not only does the fiber-reinforced resin have a low carbon fiber content rate, but when stress acts on the fiber-reinforced resin, Since cracks will be generated from the weak points that are unevenly distributed, the material will have low strength. Further, in the latter case, the floating of the woven yarn is different between the front and back of the woven fabric, and there is a problem that the cured plate is warped due to the curing shrinkage of the resin.

[0009]

DISCLOSURE OF THE INVENTION The object of the present invention is to solve the above-mentioned problems of conventional molding materials using thermoplastic fiber yarns and slit yarns and to provide FRTP having a complicated curved surface.
However, it is an object of the present invention to provide a molding material which can be easily molded and can mold FRTP having excellent mechanical properties, and a method for producing the same.

[0010]

To achieve the above object, the fiber-reinforced thermoplastic resin molding material of the present invention comprises a laminated multifilament yarn of reinforcing fibers and a thermoplastic multifilament yarn or slit yarn. It consists of a woven fabric with the body as a yarn.

The woven structure of this woven fabric is usually a flat design, but may be a twill design or a satin design, or a triaxial woven fabric,
A bias woven fabric in which warp yarns and weft yarns are arranged obliquely with respect to the length direction of the woven fabric may be used.

In the woven fabric, the cover factor occupied by the reinforcing fibers is preferably 90% or more, more preferably 95% or more. Due to such a high cover factor, the reinforcing fibers are evenly distributed over the whole when molded into FRTP, and it is possible to suppress the occurrence of resin-rich portions, and to provide a uniform and high-performance FRT.
P is obtained.

Further, such a high cover factor is easily achieved by forming the woven yarn into a laminated constitution with the above-mentioned thermoplastic multifilament yarn or slit yarn, and the reinforced fiber mulch which will be easily opened and widened as will be described later. It is more easily achieved by using filament yarn.

[0014] Incidentally, the above cover factor Cf, an element related to the size of the gap portion formed between weaving yarns, when setting a region of area S ₁ on the textile, yarn within an area S ₁ Let S ₂ be the area of the voids formed in 1. Then, the value is defined by the following equation. Cover factor Cf = [(S ₁ −S ₂ ) / S ₁ ] × 1
00 The value obtained for the reinforcing fiber is the cover factor occupied by the reinforcing fiber.

The type of reinforcing fiber is not particularly limited, and in addition to carbon fiber, glass fiber, polyamide fiber, polyaramid fiber, polyimide fiber and the like can be used.

The preferred range of volume content of the reinforcing fibers is
Although depending on the type of reinforcing fiber, it is in the range of 30 to 70%. When the reinforcing fibers are carbon fibers, the preferred volume content is 45-70%. The most characteristic features of carbon fibers are high specific strength and elastic modulus, and in order to maximize these features, it is essential to increase the carbon fiber content as much as possible. However, if a too high content rate is desired, a portion (void) where the resin does not exist is generated, and there is a problem that the strength and elastic modulus are rather lowered. Therefore, in the entire material of the present invention, the carbon fiber content is 45 to
A volume content of 70% is preferred. A more preferable range is 50 to 60%.

In the fiber-reinforced thermoplastic resin molding material of the present invention, a laminate of reinforcing filament multifilament yarns and thermoplastic multifilament yarns or slit yarns is used as the woven yarn of the woven fabric. It is preferable to use the woven yarn of this laminated structure for both the warp yarn and the weft yarn, but only one of them may be used.

The thermoplastic multifilament yarn or slit yarn is made of nylon, polyester, polypropylene, or polyether ether ketone (P
It is a multifilament yarn or slit yarn made of EEK) or the like. Regarding the thickness of the fiber yarn or slit yarn to be used, one thick fiber yarn or slit yarn may be laminated to one reinforcing fiber multifilament yarn, or a plurality of thin yarn or slit yarns may be laminated. Is also good.

Various modes can be adopted as the mode of lamination as follows. A thermoplastic multifilament yarn or slit yarn is laminated on one side of the reinforcing fiber multifilament yarn, or a thermoplastic multifilament yarn or slit yarn is laminated on both sides of the reinforcing fiber multifilament yarn. Any of these may be used. In addition, a reinforcing fiber multifilament yarn may be laminated on both surfaces of the thermoplastic multifilament yarn or slit yarn.

These laminated modes will be illustrated with reference to the drawings. FIG. 1 shows an embodiment of the fiber-reinforced thermoplastic resin molding material of the present invention, in which 1 is a warp yarn, and a thermoplastic multifilament yarn 3 is laminated on a flat reinforcing fiber multifilament yarn 2. It is what Further, 4 is a weft yarn, and like the warp yarn 1, a thermoplastic multifilament yarn 3 is laminated on the reinforcing fiber multifilament yarn 2. In this case, the thermoplastic multifilament yarn 3 may be laminated on the lower side of the flat reinforcing fiber 2 or may be laminated on both sides. Further, it may be laminated on either the warp thread or the weft thread. Further, a plurality of thin thermoplastic multifilament yarns (for example, two) may be laminated on one reinforcing fiber yarn 2.

FIG. 2 shows an embodiment in which slit yarns of a thermoplastic resin film are laminated, and 5 is a slit yarn of a thermoplastic resin film which is cut into thin pieces,
The two slit yarns 5 are aligned and laminated on the flat reinforcing fiber multifilament yarn 2. In this case, the slit yarn 5 of the thermoplastic resin film to be laminated
Although the number of the slit yarns may be one, it is possible to obtain a large amount of shear deformation at room temperature by aligning a plurality of narrow slit yarns 5.

That is, in the case of a thermoplastic slit yarn, the slit width may be the same as that of the flat carbon fiber yarn, but the shear deformability which is a feature of the present invention is regulated by the slit yarn. It is more preferable that a plurality of thin slit yarns are aligned.

As is clear from the concrete embodiments shown in FIGS. 1 and 2, the woven fabric constituting the fiber-reinforced thermoplastic resin molding material of the present invention is disclosed in Japanese Patent Publication No. 1-305101. There is a clear difference in composition from the reinforced fiber yarns and thermoplastic fiber yarns or slit yarns that are aligned in parallel, and each woven yarn has reinforced fiber multifilament yarns and thermoplastic multifilament yarns or slit yarns. It is said to be a laminated body with.

Therefore, regarding the reinforcing fiber yarn,
FRTP becomes a finely woven weave structure
Even when it is molded into a resin, it is possible to obtain a uniform and high-strength material in which the generation of resin-rich portions and voids is suppressed and the reinforcing fibers are uniformly distributed throughout.

In the fiber-reinforced thermoplastic resin molding material of the present invention, in addition to the advantages associated with the above-mentioned laminated constitution, ease of conforming to the mold at the time of molding, resin impregnation property, and higher cover factor of reinforcing fiber are desired. Be done. In order to meet such demands, the following are particularly preferable as the reinforcing fiber multifilament yarn.

That is, the focusing property is a hook drop value of 1
It is a flat, substantially non-twisted reinforcing fiber multifilament yarn in the range of 0 to 1,000 mm.

The hook drop value is a factor relating to the sizing property of the reinforcing fiber multifilament yarn, and means the value of the free fall distance of the hook measured by the following measuring method. The hook drop value is a characteristic of the reinforcing fiber multifilament yarn in the form of a woven fabric,
The measurement is performed by taking out the reinforcing fiber multifilament yarn so as not to twist the woven fabric.

First, a flat reinforcing fiber multifilament yarn having a length of 120 cm was vertically applied to the both ends of the yarn so as not to be twisted and the flat state not to be crushed under an initial load of 50 mg / denier. Fixed in the direction. Next, at a position 10 cm from the upper fixing portion of the reinforcing fiber multifilament thread being fixed, at the center of the width of the reinforcing fiber multifilament thread, hook with a metal wire diameter of 1.0 mm and a radius of 5 mm. A weight is attached with a 3 cm cotton thread, and the free fall distance of the hook is measured. In the case of thread, 10 bobbins are randomly extracted from the bobbin used, 10 measurements are made for each bobbin, and 10 bobbins are used. The hook drop value is the average value of n = 70, which is the value obtained by deleting the three largest values from the measured values. In the case of a woven fabric, three woven fabrics each having a length of 1.3 m are extracted in the length direction, and warp or weft yarns from each woven fabric are unraveled so that fluff does not occur and twist does not enter. Measurement of warp yarn or weft yarn 10 times for 1 woven fabric
N = 2, which is the value obtained by deleting the three largest values from the zero measurements
The average value of 1 is the warp or weft hook drop value. The weight of the wire and the cotton thread is made as small as possible, and the total weight of the wire, the cotton thread and the weight is 30 g.

The larger the hook drop value, the more easily the reinforcing fiber multifilament yarn is opened and widened. However, if it is too large, the shape retention of the multifilament yarn is lost, and it becomes difficult to weave a woven fabric. By setting the focusing property in the above range by the hook drop value, the optimum flat state of the woven yarn can be obtained in the form of the woven fabric, and the flat state can be maintained.

For example, in the case of making a woven fabric using carbon fiber yarn, in general, in the production process of carbon fiber, air is blown to the fiber bundle of the precursor in order to prevent a process trouble due to winding of a broken filament around a roller,
The filaments are entangled with each other to give the carbon fiber yarn a focusing property. Further, the carbon fiber yarn is provided with a sizing property by the adhesion amount of the sizing agent and the adhesion between the carbon fiber filaments. The degree of converging property is determined by the degree of entanglement between filaments, the amount of sizing agent adhered and the degree of adhesion by the sizing agent, but the hook drop value is 100 mm or less. Is too strong during hand lay-up molding or prepreg processing, the warp and weft widths of the fabric do not widen, and voids of resin are concentrated in the voids formed between the carbon fiber threads. Further, when processed into a prepreg, the impregnation property of the resin becomes poor, and a high-performance FRTP cannot be obtained. On the other hand, when the hook drop value is 1,000 mm or more, the binding property of the carbon fiber yarn is deteriorated, fluff is generated during the weaving, the working environment is deteriorated, and the FRTP strength is also decreased.

It is preferable that the woven yarn made of the reinforcing fiber multifilament yarn has substantially no twist. Here, "substantially no twist" means a state in which there is no twist of 1 turn or more per 1 m of the yarn length. In other words, it means a realistic untwisted state.

When the woven yarn is twisted, fibers crossing in the yarn width direction in the woven yarn exist in the twisted portion and the fibers are strongly aggregated, so that the resin impregnation property is deteriorated. In addition, the yarn width becomes narrow and converges and becomes thicker at the twisted portion, and unevenness occurs on the surface of the woven fabric. For this reason, in the woven fabric, stress is concentrated on the twisted portion when an external force acts, and the strength characteristics become nonuniform when molded into FRTP or the like.

Such a flat yarn enables a thin woven fabric with a wide weaving yarn interval. Therefore, since the restraint force at the intersection of the warp yarn and the weft yarn is low, it can be easily sheared and deformed. Also, since the amount of shear deformation is determined by the spacing between the weaving threads and the thickness of the threads, the spacing between the weaving threads is large,
Moreover, since it is a flat yarn, it can be deformed until the cross section of the weaving yarn becomes circular, for example, and therefore the amount of shear deformation is much larger than that of an ordinary woven fabric. As a result, the woven fabric can be made to follow a curved surface having a high curvature and can easily follow a complicated shape. As the optimum value of the shear deformation amount, it is desirable that the elongation rate in the bias direction is 25% or more.

Since the flat yarn and the thermoplastic fiber yarn or the slit yarn are laminated to form a thin woven fabric, when the woven fabric is heated to melt the thermoplastic resin, the reinforced fibers are uniformly impregnated. , FR with high performance without the occurrence of uneven distribution of resin unlike the conventional method
TP is obtained.

Even if the woven fabric substrate is composed of a flat woven yarn, if the sizing agent is firmly attached to the woven yarn or the entanglement of the reinforcing fibers is strong, the impregnation property of the resin is May interfere. However, by setting the hook drop value to 100 mm or more, the reinforcing fiber yarn is opened and widened in the state of the woven fabric, and the impregnation property of the resin can be kept extremely excellent.

The flat reinforcing fiber multifilament yarn as described above preferably has a yarn thickness of 0.07 to 0.2 mm and a yarn width / yarn thickness ratio of 30 or more. If the yarn thickness is less than the above range, it becomes too thin to maintain the shape of the flat yarn, and if it exceeds the above range, it becomes difficult to suppress the crimp to a small extent. When the yarn width / thread thickness ratio is less than 30, it is difficult to maintain both the shape of the flat yarn and suppress crimp at the same time, and to achieve the hook drop value as described above. Although the upper limit of the yarn width / thickness ratio is not particularly limited, the upper limit is about 150 in consideration of the hook drop value and the ease of performing the actual weaving process. In addition, as the yarn width, weaving is easy in the range of 4 to 16 mm.

The woven fabric according to the present invention can have various weave designs as described above, but for example, the woven yarn including the flat reinforcing fiber multifilament yarn as described above is a plain weave made into warp and weft. In this case, the fabric thickness is 0.15 to 0.6 mm and the fabric weight is 150 to 400 g /
It is preferably m ² .

In the above woven fabric, when the reinforcing fiber multifilament yarn is a carbon fiber yarn, the number of carbon fibers in the carbon fiber yarn is 5,000 to 24,000 and the fineness is 3,
It is preferably 000 to 20,000 denier.

Further, in the case of the above-mentioned fabric form, and when the flat reinforcing fiber multifilament yarn is made of carbon fiber yarn, the fabric weight and the fineness of the carbon fiber yarn as seen by the carbon fiber yarn are as follows. It is preferable that the relationship is satisfied and the cover factor occupied by the carbon fiber yarn is 95% or more. W = k · D ^1/2 However, W: fabric weight (g / m ² ) k: proportional constant (1.6 to 3.5) D: fineness of carbon fiber yarn (denier)

By using a woven fabric having such a high cover factor, a carbon fiber reinforced resin material having a high carbon fiber filling density can be obtained, and when the carbon fiber reinforced resin material is used, there are unevenly distributed portions of the resin. , The carbon fibers are evenly dispersed and become a material with high strength and elastic modulus,
High specific strength and specific elastic modulus, which are the greatest features of carbon fiber materials, are sufficiently exhibited.

As a method for producing the above flat yarn itself, for example, in the manufacturing process of the reinforcing fiber yarn,
A fiber bundle composed of a plurality of reinforcing fibers may be spread by a roll or the like to a predetermined width and kept in a flat shape, or may be held by a sizing agent or the like so as not to return to its original shape. In particular, in order to maintain the flat shape well,
It is preferable to adhere a small amount of the sizing agent of about 0.5 to 2.0% by weight to the flat yarn.

Further, as described above, when the reinforcing fiber multifilament yarn is used as the carbon fiber yarn, the carbon fiber yarn having no twist and the fineness of 3,000 to 20,000 denier is preferable, but the fineness of the yarn is final. It may be determined according to the thickness of the molded product and the cost. Particularly preferred is a carbon fiber yarn having a low fineness and a large fineness.

At this time, the carbon fiber constituting the woven yarn has a diameter of 5 to 10 μm, and is JIS-R7601.
Tensile elongation at break of 1.5 to 2.3%, tensile breaking strength of 200 to 800 kg · f / mm ² , and tensile elastic modulus of 2
It is preferably 50,000 to 70,000 kg · f / mm ² . By using such a carbon fiber, CFRTP having high mechanical properties can be obtained.

The fiber-reinforced thermoplastic resin molding material made of the woven fabric as described above is manufactured as follows. That is,
The method for producing a fiber-reinforced thermoplastic resin molding material according to the present invention comprises laminating reinforcing fiber multifilament yarns and thermoplastic multifilament yarns or slit yarns, and using this laminate as at least one of warp yarns and weft yarns. The method comprises weaving a woven fabric.

For example, as shown in FIG. 3, a conventional rapier weaving machine is used to flatten and untwist the untwisted flat reinforcing fiber yarn 10 so that the untwist does not enter the flat (horizontal) heddle 1
1 mail 11a is supplied. At the same time its reinforcing fiber yarn 1
Yarn 12 made of thermoplastic fiber so as to overlap above 0
Is supplied, and these laminated yarns are used as warp yarns 13.

At this time, the supply angles of the reinforcing fiber yarn 10 and the thermoplastic resin yarn 12 may be different. Further, as shown in FIG. 4, it is more preferable to separate the heddle mail 11a into upper and lower parts because the flat state of the reinforcing fiber yarn 10 can be surely maintained. Further, it is preferable to supply the thermoplastic fiber yarn 12 in a flat shape as much as possible, because it is easy to uniformly impregnate it when it is melted by heat, but it is narrower than the reinforcing fiber yarn 10 and is flat when melted. Since it flows above, it is not a big obstacle.

Next, in the weft yarn 16 made of a laminated body of the flat reinforcing fiber yarn 14 and the thermoplastic fiber yarn 15,
The untwisting of the weft thread does not occur due to the nip-type supply device (not shown) for picking up the weft thread bobbin while rotating it, and the pooling device (not shown) that stores the weft thread for intermittent supply of the weft thread. In this way, the rapier 18 is supplied between the warp threads 13 that are passed through the reeds 17 and opened and closed while the flat shape is not twisted. The thermoplastic fiber yarn 15 is preferably supplied in the same manner as the warp yarn, but it is placed in a vertical relationship with the reinforcing fiber yarn 14 without using the nip type supply device or the pooling device for storing the weft yarn. Two guides may be provided for feeding.

The FRTP according to the present invention is molded using the fiber-reinforced thermoplastic resin molding material composed of the woven fabric as described above. In the FRTP according to the present invention, since the reinforcing fiber yarn is laminated with the thermoplastic fiber yarn or the slit yarn, the thermoplastic fiber yarn or the slit yarn is melted and impregnated into the reinforcing fiber by directly pressurizing under heating. Then, FRTP is molded.

Since the woven yarn has a laminated structure of the reinforced fiber yarn and the thermoplastic fiber yarn or the slit yarn, the pitch between the reinforced fiber yarns can be a pitch substantially equal to the width of the reinforced fiber yarns. It can be molded while maintaining the cover factor of the high-reinforcing fiber yarn that is clogged. Therefore, even in the molded state, the reinforcing fibers are evenly distributed over the whole, the generation of resin-rich portions and voids is suppressed, and uniform and high-strength FRTP is obtained.

Further, by using the flat and substantially twist-free reinforcing fiber multifilament yarn as described above,
A very good resin impregnation property as well as a good fit property to a mold at the time of molding can be obtained. In addition, since the woven fabric has a small crimp of the weaving yarn, the unevenness is small, and the formed FRT is
As for P, a smooth surface can be obtained.

[0051]

【Example】

Example 1 Carbon fiber multifilament "Torayca" T700S-12K (fineness 7,200 denier) manufactured by Toray Industries, Inc. having a flat width of 6.5 mm and nylon multifilament "Alamin" 840- manufactured by Toray Industries, Inc. 96-700 (8
40 denier) was prepared and a warp yarn and a weft yarn were supplied according to the following method using a rapier loom, and a plain weave fabric was woven at a weaving density of 1.25 yarns / cm.

First, the carbon fiber yarn of the warp yarn was unwound by beveling, and was supplied to a heddle mail having a horizontally long rectangular shape while maintaining the flat shape of the carbon fiber. Six nylon yarns were aligned and fed so that the volume ratio with the carbon fiber yarn was 50%, and the nylon yarn was supplied to the mail above the heddle from above the carbon fiber yarn. On the other hand, for the weft yarn, the weft yarn feeding nip roller synchronized with the rotation of the loom is used to take it off at a constant speed to unwind and prevent slack from occurring in the storage device that acts on the intermittent weft yarn yarn. The flat carbon fiber yarn was supplied by a rapier so as not to be twisted. In the same manner as the warp yarn, six nylon yarns were aligned and passed through a normal tensor and a guide, placed on the flat carbon fiber woven yarn, and fed by being held by a rapier. The carbon fiber yarn used was untwisted, and the hook drop value under a load of 30 g was 220 mm.

The fabric obtained has a cover factor of 97.
%, The nylon fabric is a tightly woven fabric with few voids between the yarn and the yarn, and the nylon yarn is arranged on the flat carbon fiber yarn. This woven fabric is (0 °, 90 °) / (± 45 °)
4 sheets of / (± 45 °) / (0 °, 90 °) were cross-laminated and a press-molding method was used to obtain a cured plate having a thickness of 0.9 mm. The molding pressure was 30 kg / cm ² , and the pressing temperature was 260 ° C.

The cured plate obtained had no voids, carbon fibers were uniformly dispersed, and the surface was smooth. The tensile strength of the plate was measured in accordance with the CFRP tensile test method of JIS-K7073. The results are shown in Table 1 together with the tensile dispersibility.

Comparative Example 1 For comparison, a carbon fiber multifilament "Torayca" T700S-12K (fineness 7,200) manufactured by Toray Industries, Inc.
Denier) and Toray Co., Ltd. nylon multifilament "Amilan" 840-96-700 (840 denier) were prepared, and using a rapier loom, 1 carbon fiber yarn and 6 nylon yarns were aligned and It was woven by the usual weaving method described.

The woven structure was plain weave, and the warp and weft densities were 1.25 yarns / cm with 6 nylon yarns aligned with the carbon fiber yarns as one unit. As the warp yarn, a carbon fiber yarn and a bundle of 6 nylon yarns aligned are supplied to the mail of the same heddle, and one heddle is alternately moved up and down to form an opening, and a carbon fiber yarn is used as a weft thread in the opening. 6
Weaving was performed by feeding together a bundle of nylon yarns with uniform yarns.

The obtained woven fabric was a mesh-like woven fabric in which carbon fiber yarns and nylon yarns, or the respective yarns were integrated and bundled. Further, since the carbon fiber yarn and the nylon yarn have different tensions, they exist independently of each other in parallel with each other or twisted. Especially, in the portion where both or the carbon fiber yarns are twisted. It was getting thicker.

This woven fabric was treated in the same manner as in Example 1 (0 °, 9
0 °) / (± 45 °) / (± 45 °) / (0 °, 90
C.) and four sheets were cross-laminated and a press-molding method was used to obtain a cured plate having a thickness of 1.2 mm. In the woven state, the matrix nylon yarns are mainly present between the carbon fiber yarns, so even if the nylon yarns are melted by heat, the nylon yarns have a large movement distance to enter between the carbon fibers, and pressure is applied to the molten nylon. The impregnation was found to be inferior because it did not reach. For the above reasons, the obtained cured plate had many resin chips between the carbon fiber yarns, and many voids were also generated in the carbon fiber portions. The cured plate was subjected to JIS-K70 as in Example 1.
The tensile strength was measured according to the CFRP tensile test method of No. 73. The results are shown in Table 1 together with the tensile elastic modulus.

[0059]

[Table 1]

As can be seen from Table 1, the woven fabric base material of the present invention has excellent resin impregnation properties and high tensile properties.

[0061]

As described above, according to the fiber-reinforced thermoplastic resin molding material and the method for producing the same of the present invention, the woven yarn of the woven fabric base material is not simply aligned, but the reinforcing fiber multifilament yarn is used. Since it is a laminate with thermoplastic multi-filament yarn or slit yarn, it has excellent shearing deformability when conforming to the mold at the time of molding, and it can conform to the complicated curved mold with large curvature. In addition to being very easy to mold, the resin impregnating property is excellent, which makes the physical properties uniform and shortens the molding time, and also achieves a high reinforcing fiber cover factor and high volume content. It becomes possible to obtain FRTP having high and uniform mechanical properties.

[Brief description of drawings]

FIG. 1 is a perspective view of a fiber-reinforced thermoplastic resin molding material according to an embodiment of the present invention.

FIG. 2 is a perspective view of a fiber-reinforced thermoplastic resin molding material according to another embodiment of the present invention.

FIG. 3 is a partial perspective view of a loom showing an example of a method for producing a fiber-reinforced thermoplastic resin molding material according to the present invention.

4 is a partially enlarged vertical sectional view of the device of FIG.

[Explanation of symbols]

 1,13 Warp yarns 2,10,14 Flat reinforcing fiber multifilament yarns 3,12,15 Thermoplastic multifilament yarns 4,16 Weft yarns 5 Thermoplastic slit yarns 11 Healds 11a Heald mail

Claims (15)

[Claims] 1. A material for molding a fiber-reinforced thermoplastic resin comprising a woven fabric comprising a laminated body of a multifilament yarn of reinforcing fibers and a thermoplastic multifilament yarn or slit yarn as a woven yarn. 2. The woven fabric is flat-textured.
Fiber reinforced thermoplastic resin molding material. 3. The cover factor occupied by the reinforcing fibers is 9
The fiber-reinforced thermoplastic resin molding material according to claim 1, which is 0% or more. 4. The fiber-reinforced thermoplastic resin molding material according to claim 1, wherein the volume content of the reinforcing fibers is 30 to 70%. 5. The fiber-reinforced thermoplastic resin molding material according to claim 1, wherein the thermoplastic multifilament yarn or slit yarn is laminated on one surface of the reinforcing fiber multifilament yarn. 6. The fiber-reinforced thermoplastic resin molding material according to claim 1, wherein the thermoplastic multifilament yarn or slit yarn is laminated on both sides of the reinforcing fiber multifilament yarn. 7. The fiber-reinforced thermoplastic resin molding material according to claim 1, wherein the reinforcing fiber multifilament yarn is laminated on both surfaces of the thermoplastic multifilament yarn or slit yarn. 8. The fiber-reinforced thermoplastic resin according to claim 1, wherein a plurality of the thermoplastic multifilament yarns or slit yarns are laminated on one reinforcing fiber multifilament yarn. Molding material. 9. The reinforcing fiber multifilament yarn comprises:
The fiber-reinforced thermoplastic resin molding material according to any one of claims 1 to 8, which is a flat multi-filament yarn having a hook drop value of 100 to 1,000 mm and having substantially no twist. 10. The reinforcing fiber multifilament yarn has a yarn thickness of 0.07 to 0.2 mm and a yarn width / yarn thickness ratio of 30.
The fiber-reinforced thermoplastic resin molding material according to claim 9, which is as described above. 11. A warp yarn and a weft yarn containing the reinforcing fiber multifilament yarn, and a fabric thickness of 0.15 to 0.
The fiber-reinforced thermoplastic resin molding material according to claim 9 or 10, which has a fabric weight of 6 mm and a fabric weight of 150 to 400 g / m ² . 12. The fiber-reinforced thermoplastic resin molding material according to claim 1, wherein the reinforcing fiber multifilament yarn is a carbon fiber yarn. 13. The number of carbon fibers in the carbon fiber yarn is 5,0.
00 to 24,000, fineness of 3,000 to 20,000
The fiber-reinforced thermoplastic resin molding material according to claim 12, which has a denier of 0. 14. The carbon fiber yarn has a fabric weight and a fineness of the carbon fiber yarn satisfying the following relationship, and the carbon fiber yarn has a cover factor of 95% or more.
The fiber-reinforced thermoplastic resin molding material according to claim 12 or 13. W = k · D ^1/2 However, W: fabric weight (g / m ² ) k: proportional constant (1.6 to 3.5) D: fineness of carbon fiber yarn (denier) 15. A multifilament yarn of reinforcing fiber,
A method for producing a fiber-reinforced thermoplastic resin molding material, which comprises laminating thermoplastic multifilament yarns or slit yarns and weaving the laminate as at least one of warp yarns and weft yarns.