JPH0985841A - Fabric base composite thermoplastic plastic member and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To inexpensively prepare a fabric base composite thermoplastic plastic member being excellent as a design material or a structural material. SOLUTION: A matrix soln. 2 prepd. by dissolving polymethyl methacrylate in a volatile solvent is prepd. and a fabric base material 1 consisting of a woven fabric made of a carbon fiber is coated with the matrix soln. 2 to prepare a prepreg by evaporating preliminarily the solvent. After this prepreg is cut into a required shape, it is coated again with the matrix soln. 2 and it is cured by evaporating the solvent.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cloth-like substrate composite thermoplastic member and a method for producing the same. This cloth-like substrate composite thermoplastic resin member is suitable for use as a design material such as a panel or a structural material such as a body or a building material.

[0002]

2. Description of the Related Art Heretofore, a plastic member has been known in which a pattern is printed on the surface of a thermosetting resin or a thermoplastic resin by hydraulic transfer. Also, a plastic member is known in which a pattern is formed on a film made of polyvinyl chloride by coating and the film is laminated on an acrylic plate or the like.
These plastic members can be used as a design material because they can have a pattern of, for example, a carbon fiber woven cloth as a pattern.

On the other hand, a fiber reinforced plastic member (FRP) in which fibers are compounded with a thermosetting resin or a thermoplastic resin is widely adopted. Further, there is also known a cloth-like base material reinforced thermosetting plastic member which employs a cloth-like base material made of carbon fiber woven cloth and which is compounded with a thermosetting resin. These plastic members are suitable for use as a structural material because they have strength secured by randomly dispersed fibers or a cloth-like substrate.

[0004]

However, none of the above conventional plastic members is sufficient as a design material. That is, since the plastic member as the above design material has a flat pattern due to printing or the like,
As a design material, it cannot express depth or a sense of quality. In this regard,
The cloth-like base material reinforced thermosetting plastic member as a structural material seems to be capable of expressing a deep pattern due to the three-dimensional structure of the cloth-like base material when considering the cloth-like base material as a pattern. Since the cloth-like base material is not bonded to the thermosetting resin by the pressure of the press working, the cloth-like base material cannot maintain the three-dimensional structure. Further, this plastic member requires the addition of an initiator or a catalyst for the polymerization and curing of the thermosetting resin,
Many of these initiators have a color, and in the case of a catalyst, the edge of the cloth is often changed, which impairs the transparency and luster of the matrix, so that the cloth-like substrate looks cloudy and the surface has no luster. It becomes a thing. In addition, the above-mentioned conventional FR
In P, fibers and the like cannot be regarded as patterns.

Further, since the above-mentioned conventional plastic member as a structural material requires press working or injection molding at the time of manufacturing, it requires large-scale equipment and the manufacturing cost rises. Further, the fibers (yarns, tows) constituting the woven or non-woven fabric may interfere with each other due to the pressing of the cloth-like base material, and may be damaged or crushed, and there is a concern that the bending strength and the like may decrease.

Further, when a cloth-like base material is adopted, the manufacturing cost rises unless the cloth-like base material is cut into substantially the same shape as a desired shape with a high yield. This is because, in particular, a cloth-like substrate made of carbon fiber woven cloth is expensive.
Further, if the cloth-like base material is a woven cloth, the stitches are unraveled when the cloth-like base material is cut into a desired shape, and the designability is impaired. The present invention has been made in view of the above conventional circumstances, and an object of the present invention is to inexpensively manufacture a cloth-like base material composite thermoplastic member excellent as a design material or a structural material.

[0007]

[Means for Solving the Problems]

(1) The cloth-like substrate composite thermoplastic resin member according to claim 1, wherein a cloth-like substrate made of a woven fabric or a non-woven fabric, and a thermoplastic resin impregnated inside the cloth-like substrate and formed on the surface thereof. And a matrix made of a cloth-like base material composite thermoplastic resin member, wherein the cloth-like base material maintains a three-dimensional structure.

(2) The cloth-like base material composite thermoplastic resin member according to claim 2 is the cloth-like base material composite thermoplastic resin member according to claim 1, wherein the cloth-like base material is woven cloth,
The matrix is characterized in that it is formed so as to wrap around the end of the cloth-like substrate. (3) A method for producing a composite thermoplastic material member having a cloth-like substrate according to claim 3, comprising a cloth-like substrate made of woven cloth or non-woven cloth,
Prepare a matrix solution in which a thermoplastic resin is dissolved in a volatile solvent, apply the matrix solution to the cloth-like substrate, and obtain a prepreg in which the solvent is pre-evaporated, and the prepreg is desired. A second step of cutting into a shape to obtain a cut prepreg, and a third step of applying the matrix solution again to the cut prepreg and curing the solution by volatilization of the solvent to obtain a cloth-like substrate composite thermoplastic member And are included.

When the cloth-like substrate composite thermoplastic resin member is manufactured by the manufacturing method according to claim 3, first of all,
In the step, the cloth-like substrate is coated with the matrix solution. Here, a woven fabric or a non-woven fabric can be adopted as the fabric substrate. Woven fabric is made of regularly woven tows, which are made up of hundreds or thousands of yarns. Nonwoven fabrics are yarns or tows that are randomly integrated. As the woven or non-woven fabric, those made of carbon fiber, those made of aromatic polyamide fiber (aramid fiber), those made of glass fiber, those made of ceramic whiskers, those made of metal whiskers, etc. can be adopted.

The matrix solution is a volatile solvent in which a thermoplastic resin is dissolved. As the thermoplastic resin, polyethyl methacrylate (acrylic resin), acrylonitrile-butadiene-styrene resin (ABS), polystyrene (PS), polycarbonate (PC), polyvinyl chloride (PVC), polyamide (PA), etc. can be adopted. When the fabric-like base material is made of carbon fiber and the design material is manufactured, since the carbon fiber has good wettability with respect to the thermoplastic resin and easily penetrates into the matrix material, a surfactant is added to the matrix solution. It is not necessary to add it, but when manufacturing a structural material or when the cloth-like substrate is glass fiber, ceramic whiskers, metal whiskers, or the like, an appropriate surfactant is added to the matrix solution. Here, the limit of the viscosity of the matrix solution can be determined as follows.

That is, the required intrinsic viscosity is η (cp
s), the concentration is C (g / 100 cc), and the converted viscosity is η
_sp (cps), constant C → 0,

[0012]

[Equation 1]

The equation (1) is established. Further, if the dissolution constant is K, the molecular weight of the thermoplastic resin is M, and the constant determined by the type of thermoplastic resin is a,

[0014]

[Equation 2] η = K · M ^a (2) Formula is established. Here, the value of a is 0.5 for a free-flexible thread-mull molecule, 2.0 for a completely rigid molecule, and 0.5-1.0 for an ordinary polymer, which varies depending on the solvent.

In formulas (1) and (2), C = 0 is used to obtain the intrinsic viscosity, and the repelling constant K ≧ 1 is set because the solvent is a solvent capable of dissolving the thermoplastic resin, and the thermoplastic resin is a flexible yarn. If the thermoplastic molecule is a = 0.5, if the thermoplastic resin is a rod-shaped molecule (linear), a = 2.0, and if the thermoplastic resin is a normal polymer (polymer), a = 0.5 to 1. A matrix solution satisfying these conditions is prepared. Such a matrix solution can be used from low molecular weight thermoplastic resins to high molecular weight thermoplastic resins. However, if the thermoplastic resin is a copolymer, further examination is required to clarify the distinction between the design material and the structural material. From the above, if commercially available polymethylmethacrylate is adopted as the thermoplastic resin, it becomes a liquid when η <50 and a solid when η> 50 with the intrinsic viscosity η = 50 as a boundary.
It is understood that a matrix solution having η smaller than 50 can be adopted.

In this way, when the matrix solution is applied to the cloth-like substrate, the solid content of the thermoplastic resin in the matrix solution is scattered as the binder between the tows and the yarns.
Then, the solvent preliminarily volatilizes with the lapse of time to obtain a prepreg. Next, in a second step, the prepreg is cut into a desired shape to obtain a cut prepreg. At this time,
Since the solvent is preliminarily volatilized, the cloth-like substrate is in a semi-raw state, and can be cut into almost the same shape as the desired shape, thus improving the yield. Further, if the cloth-like substrate is a woven cloth, the stitches will not be loosened at this time.

It is also possible to adhere a backing sheet to the back surface of the prepreg before the second step. In this case, it is possible to prevent the fibers from missing. Also,
When the cloth-like base material composite thermoplastic member according to the present invention is used as a structural material by using a plurality of cloth-like base materials, a plurality of cut prepregs may be stacked in the second step.

After this, in the third step, the above matrix solution is applied again to the cut prepreg. As a result, the solid content in the first step comes into contact with the re-applied matrix solution, the molecules of the solid content in the first step are activated, and are easily entangled with the molecules of the solid content in the third step. At this time, three-dimensional deformation is possible by deformation before curing. The thickness of the matrix on the surface of the plastic member can be changed by the coating thickness of the matrix solution at this time. For example, if you apply thinly, the surface matrix becomes thin,
The three-dimensional effect of the cloth-like substrate appears on the surface of the matrix.

The solvent volatilizes over time,
The molecules of the solid content in the first step and the molecules of the solid content in the third step are intertwined and cured. After this, it can be cut into its final shape. Thus, the cloth-like substrate composite thermoplastic member according to claim 1 is obtained. In this plastic member, the cloth-like base material and the matrix are chemically bonded by entanglement of the molecules of the thermoplastic resin, not by mechanical bonding by press working as in the conventional case. Also, at this time, equipment such as press processing is not required,
Moreover, these operations can be performed at room temperature.

In the plastic member according to the first aspect of the present invention, since the cloth-like base material maintains the three-dimensional structure as it is and does not require the addition of the curing initiator, the transparency and luster of the matrix are not impaired and the cloth member is not damaged. Since the shaped base material is transparent and has a glossy surface, it can be used as a design material to express depth and a sense of quality. Further, in the plastic member of claim 1, fibers (yarns, tows) constituting the woven or non-woven fabric of the cloth-like base material do not interfere with each other, are not easily scratched, and are not crushed. There is no.

In the third step, it is also possible to apply the matrix solution again to the cut prepreg and then laminate the transparent resin plate on the surface side. If this transparent resin plate is of the same type as the thermoplastic resin of the matrix solution, the molecules of the solid content in the third step play a role of crosslinking,
When cooled, both molecules are entangled and integrated. At this time, three-dimensional deformation is possible by heating the transparent resin plate. Further, the thickness of the transparent resin plate can change the thickness of the matrix on the surface of the plastic member.
For example, if a thin transparent resin plate is adopted, the surface matrix becomes thin, and the three-dimensional effect of the cloth-like substrate appears on the surface of the matrix. In this case, if the cloth-like base material is a woven cloth, the cloth-like base material composite thermoplastic resin member according to claim 2 can be obtained.

In the plastic member of the second aspect, the matrix is formed so as to wrap around the end of the cloth-like base material made of woven cloth, so that the stitches are firmly maintained even at the end. It should be noted that whether the plastic member according to the present invention is a design material or a structural material can be determined in consideration of the following points.

That is, the design material and the structural material can be classified according to the use, but can also be classified according to whether or not the thermoplastic resin is contained in an amount that cannot include the fiber yarn. At this time, when the plastic member contains 3 to 50 wt% of the thermoplastic resin, the plastic member can be classified as a design material. Further, when the plastic member contains 30 to 80 wt% of the thermoplastic resin, the plastic member has a high bending elastic strength and can be classified as a structural material.

Further, the plastic member according to the present invention is
In general, since a viscous thermoplastic resin is used as compared with a brittle thermosetting resin, a great advantage as a structural material is expected. However, the strain of the entire plastic member is ε _c , the strain of the yarn is ε _y , and the strain of the thermoplastic resin is ε _m.
Then, since ε _c = ε _y = ε _m , if the strength of the thermoplastic resin is not so high that the strength of the yarn increases when the fiber direction is taken into consideration, then when the plastic member is used as the structural material, The advantage is reduced.

[0025]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments in which the inventions of claims 1 to 3 are embodied as a design material for an instrument panel of a vehicle will be described below with reference to the drawings. “First Step” First, as shown in FIG. 1A, a carbon fiber woven cloth is prepared as the cloth-like substrate 1.

Further, polymethylmethacrylate as a thermoplastic resin and toluene, methanol, xylol and tetrahydrafuran (THF) as volatile solvents were prepared, and 85 wt% of the volatile solvent had a solid content of 15% of polymethylmethacrylate. % Is dissolved, and η = 300 (cp
The matrix solution 2 of s) is used. Volatile solvents are 80 wt% toluene, 3 wt% methanol and 3 wt xylol.
% And 14 wt% of THF.

Then, the matrix solution 2 is applied to the cloth-like substrate 1 by using a spray gun. At this time, the cloth-like substrate 1
The matrix solution 2 was slightly spread on the surface of the. As a result, as shown in FIGS. 8 and 9, the tow 1a and the yarn 1b are
Between them, the solid content 2a of polymethylmethacrylate in the matrix solution 2 is scattered as a binder. Then, as shown in FIG. 1 (B), PV is applied to the back surface of the cloth-like substrate 1.
The backing sheet 3 made of C is bonded using a weak adhesive. The solvent evaporates over time while doing this,
Obtain prepreg 4. "Second step" Next, as shown in FIG.
Is clamped between the upper and lower dies 5 and 6 and cut into a desired shape to obtain a cut prepreg 7. At this time, since the backing sheet 3 is adhered to the back surface of the prepreg 4 and the solvent is pre-evaporated, the cloth-like substrate 1 is in a semi-lived state, cut and cut into a shape almost equal to the desired shape, and the yield is improved. ing. In addition, the cloth-like substrate 1 was not loosened at this time. [Third step] After that, as shown in FIG. 3, the matrix solution 2 is cut on the cut prepreg 7 using a spray gun.
Reapply. Also in this case, the matrix solution 2 was thinly spread on the surface of the cloth-like substrate 1. As a result, FIG. 8 and FIG.
As shown in FIG. 3, the solid content 2a in the first step is brought into contact with the re-applied matrix solution 2, and the solid content 2a in the first step is
The molecules of a are activated and become entangled with the molecules of the solid content 2a in the third step.

Next, as shown in FIG. 4, the cut prepreg 7 to which the matrix solution 2 has been applied again is placed on the shaping table 8 in a heating vacuum device (not shown). An acrylic resin plate 10 heated by a far infrared lamp 9 is provided above the shaping table 8, and an air vent hole connected to a vacuum pump (not shown) is provided below the shaping table 8.
At this time, the acrylic resin plate 10 having a thickness of 1 mm was adopted. Then, while heating the acrylic resin plate 10, air is extracted from the air vent hole.

During this period, as shown in FIGS. 8 and 9, the cut prepreg 7 is three-dimensionally deformed on the shaping table 8 by the deformation before curing, and the solvent is volatilized with the lapse of time, so that the first step The molecule of the solid content 2a and the molecule of the solid content 2a in the third step are cured in a state of being intertwined with each other. Further, as shown in FIG. 5, the acrylic resin plate 10 is laminated on the front surface side of the cut prepreg 7. As shown in FIG. 7, the acrylic resin plate 10 has a matrix solution 2
Since it is of the same type as that of polymethylmethacrylate, the molecules of the solid content 2a in the third step play a role of crosslinking, and when cooled, both molecules are entangled and integrated.

After this, as shown in FIG. 6, it is cut into a final shape to obtain a design material 11 for an instrument panel of a vehicle. During this period, the time is about 120 to 360 seconds, which is 1/100 to 1/1000 of that of the conventional hydraulic transfer.
Was short. In this design material 11, the cloth-like base material 1 and the matrix 2 are chemically bonded by entanglement of polymethylmethacrylate, not by mechanical bonding by press working as in the conventional case. Further, at this time, these operations can be performed at room temperature without requiring equipment such as press working.

In the design material 11, as shown in FIG. 7, the cloth-like base material 1 maintains the three-dimensional structure as it is,
Since no addition of a curing initiator was required, the transparency and luster of the matrix 2 were not impaired, and the cloth-like substrate 1 was transparent and the surface was glossy. In particular, since the matrix solution 2 is thinly applied in the third step and the thin acrylic resin plate 10 is used, the matrix 2 on the surface becomes thin and the three-dimensional effect of the cloth-like substrate 1 appears on the surface of the matrix 2. Was there. For this reason, when this design material 11 was bonded to an instrument panel of a vehicle, it was difficult to totally reflect light from all directions due to the unevenness of the surface of the matrix 2. Therefore, in this design material 11,
The three-dimensional effect of the cloth-like base material 1 inside is clear, the depth and high-class feeling can be expressed as the design material 11, and the viewer can be attracted from a distance.

As shown in FIG. 6, since the matrix 2 is formed around the end portion 1a of the cloth-like base material 1 in the design material 11, the stitches are firmly maintained even at the end portion 1a. It had been. Therefore, also in this respect, the design material 11 attracts the viewer, and the end portion treatment is not necessary, and the manufacturing is easy. As another design material, for example, when the invention of each claim is embodied on a table, the matrix solution 2 is used in the third step.
Is thickly applied and the thick acrylic resin plate 10 is used, the matrix 2 on the surface becomes thick and the surface can be formed smooth. As described above, the invention can be embodied in other design materials, structural materials such as bodies and building materials, and the like.

[0033]

As described in detail above, the plastic member of claim 1 is excellent as a design material or a structural material because the cloth-like base material maintains a three-dimensional structure. Especially,
The plastic member according to the second aspect has the stitches firmly maintained even at the end portion, so that the plastic member exhibits more excellent designability and is easy to manufacture because the end portion treatment is unnecessary.

According to the manufacturing method of claim 3, the cloth-like substrate composite thermoplastic resin member of claims 1 and 2 can be manufactured at low cost. In addition, this manufacturing method can exert such an effect even if it has a large size, a large area, or a complicated shape.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a state in which a cloth-like substrate is coated with a matrix solution according to the embodiment, and (B) is a schematic cross-sectional view of a prepreg to which a backing sheet is adhered.

FIG. 2 is a schematic cross-sectional view of a state in which a prepreg is cut according to the embodiment.

FIG. 3 is a schematic cross-sectional view of a state in which the matrix solution is applied again to the cut prepreg according to the embodiment.

FIG. 4 is a schematic cross-sectional view showing a state in which transparent resin plates are laminated according to the embodiment.

FIG. 5 is a schematic cross-sectional view showing a state in which transparent resin plates are laminated according to the embodiment.

FIG. 6 is a schematic cross-sectional view of the plastic member of the embodiment.

FIG. 7 is an enlarged schematic cross-sectional view of a surface portion according to the plastic member of the embodiment.

FIG. 8 is a further enlarged schematic cross-sectional view of FIG. 7 according to the plastic member of the embodiment.

9 is a further enlarged schematic cross-sectional view of FIG. 8 according to the plastic member of the embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Cloth-like base material 2 ... Matrix, matrix solution 11 ... Design material (cloth-like base material composite thermoplastic member) 3 ... Backing sheet 4 ... Prepreg 7 ... Cut prepreg 1a ... Edge

Claims (3)

[Claims] 1. A cloth-like substrate composite heat comprising a cloth-like substrate made of a woven or non-woven fabric, and a matrix made of a thermoplastic resin which is impregnated inside the cloth-like substrate and formed on the surface thereof. A plastic-plastic member, wherein the cloth-like base material maintains a three-dimensional structure. 2. The composite thermoplastic material for a cloth-like substrate according to claim 1, wherein the cloth-like substrate is a woven cloth, and the matrix is formed so as to wrap around an end portion of the cloth-like substrate. Plastic material. 3. A cloth-like base material made of a woven or non-woven fabric and a matrix solution in which a thermoplastic resin is dissolved in a volatile solvent are prepared, and the matrix solution is applied to the cloth-like base material.
A first step of obtaining a prepreg in which the solvent is pre-evaporated, a second step of cutting the prepreg into a desired shape to obtain a cut prepreg, and the matrix solution is re-applied to the cut prepreg to remove the solvent. A third step of curing by volatilization to obtain a cloth-like base material composite thermoplastic member, and a method for producing a cloth-like base material composite thermoplastic resin member.