JPH106421A - Fiber composite sheetlike material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel fiber composite sheetlike material excellent in surface characteristics (sensitivity) such as aesthetic properties, design effect or the feel and capable of being suitably used in a field of a tile wall material or the like. SOLUTION: A fiber composite sheetlike material is a sheet material wherein at least one layer of a fabric composed of thermoplastic resin fibers having an m.p. higher than that of a thermoplastic resin being a matrix component by 5 deg.C or higher or non-hot-melt fibers is laminated to the matrix component composed of the thermoplastic resin and at least a part of the surface of the fabric is exposed to at least one surface of the sheetlike material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet material in which a fabric is combined with a thermoplastic resin. For more information,
Part of the surface of the cloth is exposed on the surface of the sheet-like material, and it is excellent in aesthetics and design and has a good tactile sensation when touched by hand. The present invention relates to a fiber composite sheet material.

[0002]

2. Description of the Related Art Conventionally, sheet-like composite materials containing a reinforcing fiber layer using a thermosetting resin or a thermoplastic resin as a base resin are well known and widely used. For example, a composite material having a thermosetting resin as a base resin is formed by laminating a tape-shaped or flat prepreg obtained by impregnating or applying a thermosetting resin to a reinforcing fiber tow or a woven fabric, if necessary. It is made by curing the resin after making it into the shape of a molded product by a mold or the like. However, this includes poor handling due to the high adhesiveness of the prepreg, difficulty in shaping once it has been thermally cured, and the resulting composite material has an inorganic, cold-looking appearance and plastic-like appearance. There are problems such as having an unpleasant feel.

On the other hand, a composite material using a thermosetting resin as a base resin is disclosed in Japanese Patent Application Laid-Open No. 1-278336, for example, in which a laminate of a thermoplastic resin fabric and a reinforcing fiber fabric is molded by a mold or the like. Method for pressure molding, Japanese Patent Laid-Open No. 3-69629
Japanese Patent Application Laid-Open Publication No. Hei. -8
No. 0652 discloses a method in which a layer made of reinforcing fibers and thermoplastic resin fibers is provided on the surface of a mat-like material obtained by subjecting a web made of reinforcing fibers and thermoplastic resin fibers to entanglement treatment, followed by pressure thermoforming. Proposed. However, all of the sheet-like composite materials obtained by these methods are intended to improve the handleability at the time of molding or the rigidity and strength of the composite material, and are similar to the case of using the above-described thermosetting resin. ,
The surface had problems such as an inorganic and cold appearance and a plastic-like feel.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above background, and has as its object to provide excellent surface properties such as aesthetics, design, and tactile sensation that have been increasing in various fields in recent years. It is to provide a novel fiber composite sheet material.

[0005]

Means for Solving the Problems The object of the present invention is to provide:
"A matrix component composed of a thermoplastic resin, a thermoplastic resin fiber having a melting point of 5 ° C. or more higher than the thermoplastic resin, or a sheet material in which at least one layer of a fabric composed of non-thermofusible fibers is composited, At least one surface of the fabric is exposed on at least one surface of the sheet material. "

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The resin used for the matrix component of the present invention must be a thermoplastic resin which can be melted and shaped by heating, and particularly preferably a resin which is hardly thermally decomposed even by heat treatment. . When the matrix component is a thermosetting resin, not only is the handleability poor, but also
The impact resistance of the obtained molded article is lowered, and the article which has been thermoformed once in a sheet shape is not preferable because it becomes difficult to re-mold it into another form.

Examples of the thermoplastic resin preferably used for the matrix component include polyolefins such as polyethylene, polypropylene and polybutylene, polyamides such as nylon 4, nylon 6, nylon 66 and nylon 610, and polyethylene terephthalate.
Polyesters such as polytetramethylene terephthalate,
In addition, copolymers of these polymers can be mentioned, and the melting point of such a copolymer can be adjusted by adjusting the copolymerization ratio.

[0008] The fibers constituting the fabric composited with the matrix component are thermoplastic resin fibers having a melting point higher than that of the matrix component by 5 ° C or more or non-heat-fusible fibers, preferably 5 ° C or higher than the matrix component. It is necessary that the thermoplastic resin fiber has a high melting point of not higher than ° C. When the resin has a melting point and its temperature is not higher than the melting point of the matrix component by 5 ° C. or more, when the matrix component and the fabric are combined, the shape of the fabric changes or the fiber properties change. A sufficient reinforcing effect cannot be obtained, and the cloth disposed on the outermost layer of the sheet material is easily melted, so that the desired surface characteristics of the present invention cannot be obtained.

As the thermoplastic resin preferably used for the cloth, for example, polyolefin such as polyethylene, polypropylene and polybutylene, or nylon 4,
Examples thereof include polyamides such as nylon 6, nylon 66, and nylon 610, and polyesters such as polyethylene terephthalate and polytetramethylene terephthalate.

On the other hand, examples of the non-heat-fusible fibers include meta- or para-based aromatic polyamide fibers, cellulose fibers such as cotton and hemp, cellulose derivative fibers such as rayon, and protein fibers such as silk and wool. Can be. In addition, a pitch-based or PAN-based carbon fiber or the like can be used together for reinforcement inside the sheet material that is not exposed to the surface layer.

The fabric used in the present invention is not particularly limited as long as it is composed of the above-mentioned thermoplastic resin fibers or non-thermofusible fibers. However, a woven or knitted fabric, particularly a composite sheet material from which a woven fabric can be obtained, is preferred in terms of aesthetics and design. It may be a fabric in which two or more kinds of fibers are mixed, mixed or interwoven.

In the present invention, one of these cloths is used.
Alternatively, a plurality of sheets are laminated in layers to be composited with the matrix component. At this time, as the cloth positioned on the surface layer of the composite material, a cloth made of a natural material such as cotton, hemp, silk, and wool, and a cloth made of a semi-synthetic fiber such as acetate and rayon has an aesthetic property, a design property, and a feeling such as touch. It is preferable from the viewpoint. Further, the fabric located on the surface layer is preferably a sensible material usually used for clothing or the like, and an aesthetic or design property improved by dyeing or printing.

When a plurality of fabrics are laminated and used, the fabric located in the inner layer is composed of high-strength fibers, for example, para-aromatic polyamide fibers, etc. Is preferred because the strength of the resin is improved.

In the fiber composite sheet material of the present invention, it is important that at least a part of the cloth is exposed on at least one surface of the sheet material. When the fabric is completely buried in the matrix component, the visual surface effects (aesthetics) such as warmth and softness of the fabric and the unique tactile sensation when touched by hand are not obtained. It is not preferable. When the outermost layer of fabric is partially completely impregnated, not only adhesiveness but also a new design effect can be obtained, which is preferable. Therefore, it is desirable that the area ratio of the completely impregnated fabric is less than 50%.

In the fibrous composite sheet material of the present invention, when the impregnation rate of the matrix component with respect to the outermost fabric is reduced, the adhesiveness between the fabric and the matrix for producing a surface effect is insufficient. The fabric layer on the outermost layer is easily peeled off during handling after molding or during use of the product. On the other hand, when the impregnation ratio is increased, the surface effects such as aesthetics, design, and tactile sensation of the fabric are obtained. , The impregnation rate of the matrix component into the outermost layer fabric is 1
It is preferably in the range of 0 to 90%, especially 30 to 50%.

Here, the impregnation ratio represents the ratio of the thickness of the matrix component permeated into the outermost fabric. That is, the impregnation ratio is determined by reading the distance from the lowest point to the highest point of the outermost layer fabric from the cross-sectional electron micrograph of the obtained sheet-like material and defining the distance as the outermost layer fabric thickness, while determining the maximum value in the resin layer. The distance from the lowermost point of the surface fabric to the uppermost point of the matrix component layer inside the outermost fabric was read and calculated as the matrix component penetration thickness penetrating into the innermost fabric. Impregnation rate (%) = 100 x (thickness of matrix component penetration)
/ (Outermost layer fabric thickness)

The method for producing the fiber composite sheet material of the present invention described above is not particularly limited, and any method may be used. For example, a film, sheet or fabric made of a thermoplastic resin is alternately laminated with a reinforcing fabric,
At this time, a fabric rich in design is arranged on the outermost layer, and then heated at a temperature higher than the melting point of the thermoplastic resin on the low melting point side as the matrix component and lower than the melting point of the fibers on the high melting point side constituting the fabric. A method of performing molding by pressing, or melting and impregnating a thermoplastic resin serving as a matrix component into a reinforcing cloth, laminating the required number of layers, and then arranging a cloth rich in surface effect on the outermost layer, Examples of the method include a method in which molding is performed even after pressing, and a method in which these are continuously subjected to hot press molding using a hot roll or the like. At this time, depending on the usage ratio of the thermoplastic resin serving as the matrix component, the bulk density of the fabric to be used, and the type of the fiber, it is possible to select and set the hot press temperature and the pressurizing conditions, so that the surface of the fiber composite material is It is important to expose a part to achieve the object of the present invention.

[0018]

The present invention will be described in more detail with reference to the following examples. In addition, each measurement item in an Example followed the following measuring method. <Melting point> The melting point of the thermoplastic resin was estimated from the position of the melting point endothermic peak using a DSC measurement device (TG8110D, manufactured by Rigaku Corporation). <Impregnation rate> The impregnation rate of the matrix component is determined by taking a cross-sectional electron micrograph of the obtained fiber composite sheet material, reading the distance from the lowest point to the highest point of the outermost fabric, and reading the outermost fabric thickness. On the other hand, the distance from the lowermost point of the outermost layer fabric in the resin layer to the uppermost point of the matrix component layer inside the outermost layer fabric is read, and as a matrix component penetration thickness that has penetrated into the outermost layer fabric, It was calculated from the following equation. Impregnation rate (%) = 100 x (thickness of matrix component penetration)
/ (Outermost layer fabric thickness)

<Surface Effect> The area of the portion where the matrix resin exudes on the surface of the cloth disposed on the outermost surface of the sheet material is measured, and the ratio of the exuded area to the total surface area of the sheet material is 60%. %, It was determined to be good, and if it exceeded 60%, it was determined to be poor. <Surface Peeling> Based on JIS K 6854, the peel strength between the outermost layer fabric and the base portion was measured. If the strength was 40% or more of the tensile strength of the fabric disposed on the outermost layer, it was good. %, It was determined to be defective.

[Examples 1 and 2, Comparative Example 1] 25 cm × 2
5 cm polyethylene terephthalate (PET: melting point 2)
PET / Ny6 = 2/3 sheets of taffeta (basis weight: 60 g / m ² ) made of fiber and nylon 6 (Ny6: melting point: 222 ° C.) taffeta (basis weight: 65 g / m ² ) alternately laminated. Then, the number of PET taffeta shown in Table 1 was laminated on the outermost layer, and the pressure was reduced to 50 by a hot press.
Hot pressing was performed at Kg / cm ^{2 at} a temperature of 230 ° C. for 10 minutes to obtain a sheet. Table 1 shows the results.

Comparative Example 2 The fabric to be laminated on the outermost layer was N
A sheet was obtained in the same manner as in Example 1 except that a taffeta made of y6 fiber was used. The results are shown in Table 1.

[Examples 3 and 4] The fabric to be laminated on the outermost layer is as shown in Table 1 (however, cotton fabric has a basis weight of 150 g /
m ² , and the linen fabric was changed to a basis weight of 140 g / m ² ) to obtain a sheet-like material in the same manner as in Example 1. The results are shown in Table 1.

[0023]

[Table 1]

[0024]

According to the fiber composite sheet material of the present invention, since a part of the composite fabric is exposed on the surface thereof, the sensitivity, which was not considered at all in the field of the conventional fiber reinforced film or sheet material, That is, it has surface characteristics unique to the fabric, such as aesthetics, design, and feel. Therefore,
Taking advantage of these characteristics, it can be used in fields such as tile wall materials.

Claims (3)

[Claims] 1. A sheet material in which at least one layer of a thermoplastic resin fiber having a melting point higher by 5 ° C. or more than a thermoplastic resin or a non-thermofusible fiber is composited with a matrix component composed of a thermoplastic resin. The fiber composite sheet material, wherein at least a part of the surface of the cloth is exposed on at least one surface of the sheet material. 2. The fiber composite sheet material according to claim 1, wherein an exposure ratio of the fabric surface is 40 to 100% based on the fabric area. 3. The fiber composite sheet material according to claim 1, wherein the impregnation rate of the matrix component impregnated in the fabric disposed on the outermost layer of the fiber composite sheet material is 10 to 90%.