JPH11333956A - Three dimensional molded body of net structure consisting of continuous fiber reinforced thermoplastic resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional molded body capable of being used in various uses of a net structure, in which a continuous fiber reinforced thermoplastic resin, improved in rigidity, tensile strength, creep characteristic and the like remarkably, is reticulated. SOLUTION: Single yarn, constituting the three-dimensional molded body of a net structure consisting of continuous fiber reinforced thermoplastic resin, includes a core material layer consisting of tape type or linear matter, consisting of a continuous fiber reinforced material drawn and aligned substantially in parallel to the lengthwise direction of the same and impregnated with thermoplastic resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin. More specifically, the present invention relates to a three-dimensional molded article obtained by shaping a net structure made of a continuous fiber reinforced thermoplastic resin having excellent rigidity, tensile strength and creep characteristics.

[0002] A molded product obtained by shaping a net structure three-dimensionally can be used in various applications such as a pipe reinforcing material formed into a tubular shape and a box-shaped snake cage and a fish reef.

[0003]

2. Description of the Related Art Conventionally, a so-called fiber-reinforced thermosetting resin (FRP) using a thermosetting resin as a matrix resin cannot be reshaped once molded. In the case of such an FRP, the semi-cured state is formed into various shapes and then cured. This semi-cured state cannot only be stored for a long period of time, but also has the drawback of poor workability and handling because it is in a semi-cured state. Disposal /
Recyclability is also an issue.

Further, a so-called fiber-reinforced thermoplastic resin (FRTP) using a thermoplastic resin as a matrix resin,
It has little effect on the environment and can be recycled. However, the reinforcing fibers in the matrix resin are further shortened because the reinforcing fibers cut in advance and the thermoplastic resin are kneaded. For this reason, although improvement in performance such as rigidity and tensile strength is observed, the degree is not as high as FRP.

Japanese Patent Application Laid-Open No. 7-173824 discloses a reinforced net using continuous glass fibers, which is obtained by forming a plurality of holes in a continuous glass fiber reinforced sheet. is there. Japanese Patent Application Laid-Open No. 7-173824 discloses a fiber grid in which a thermosetting resin or a thermoplastic resin is reinforced with continuous fibers and integrally molded into a grid in order to provide high strength, high elastic modulus and high creep characteristics. doing.

However, to date, there is no idea that if a net structure made of a continuous fiber reinforced thermoplastic resin is three-dimensionally formed and used for various purposes, it can be a useful structural material. The conditions that satisfy such conditions have not been known.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to provide a continuous fiber reinforced thermoplastic resin having significantly improved rigidity, tensile strength and creep characteristics. An object of the present invention is to provide a three-dimensional molded body which can be used for various uses of a net structure having a net shape.

[0008]

The present invention has the following constitution. 1) A three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin, wherein a single yarn constituting the net structure is formed into a continuous fiber reinforced material that is aligned substantially parallel to its length direction. A three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin, comprising a core material layer which is a tape or a linear material impregnated with a thermoplastic resin.

2) The three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin as described in 1) above, wherein the single yarn has a resin skin layer formed on the surface of the core material layer. . 3) The average thickness of the resin skin material layer is 0.03 to 1.0.
mm, a three-dimensional molded article of a net structure made of the continuous fiber-reinforced thermoplastic resin according to the above item 2).

4) The single yarn is characterized in that at least one of the single yarns has a thickness of 0.2 to 2.0 mm.
A three-dimensional molded article of a net structure comprising the continuous fiber-reinforced thermoplastic resin according to any one of 3). In the present invention, a single yarn made of a continuous fiber reinforced thermoplastic resin for forming a net structure is a tape or a continuous fiber reinforced material that is impregnated with a thermoplastic resin in a continuous fiber reinforcement material aligned substantially parallel to its length direction. It includes a core material layer that is a linear object. That is, since the single yarn includes a thermoplastic resin as a matrix resin and a continuous fiber reinforced thermoplastic resin with a continuous fiber as a reinforcing material, a net structure in which the single yarn including the core layer is formed into a net is lightweight. It has excellent performance such as rigidity, tensile strength and creep. The three-dimensional molded product of this net structure is a lightweight product having excellent properties such as rigidity, tensile strength and creep characteristics, as well as excellent pressure resistance. Furthermore, since it is solventless, it has little effect on the surrounding environment. Since the matrix resin is a thermoplastic resin, it can be reused as FRTP by re-pelletizing the molded product by grinding or the like.

The single yarn constituting this net structure is a tape or a linear material. Here, the linear object has an arbitrary cross-sectional shape in the width direction, and for example, refers to a long body such as a polygon such as a circle, an ellipse, a rectangle, and a triangle. In the present invention, the single yarn may be only the core material layer, but it is preferable that the surface of the core material layer is covered with a resin skin layer.

The single yarn preferably has a thickness of at least one single yarn of 0.2 to 2.0 mm, more preferably 0.3 to 2.0 mm.
１．０1.0 mm. Also, the thickness of the resin skin layer is
0.3 to 1.0 mm is preferred, and more preferably 0.1 to 0.5
mm is preferred. If the thickness of the single yarn is less than 0.2 mm, it is difficult to process the net and the rigidity tends to be low. Further, when the thickness of the single yarn is greater than 2.0 mm or when the thickness of the resin skin material layer is greater than 1.0 mm, it becomes difficult to perform heating.

When the single yarn is in a tape shape, its width is
Usually, it is selected from a range of about 5 to 30 mm, and in the case of a linear object, the maximum diameter of the width is usually selected from a range of about 2 to 50 mm. The single yarn may be obtained by simply bundling or twisting two or more single yarns of the above-mentioned unit, or by heat-sealing them. It can be used as a constituent single yarn or as an element of a net structure together with the unit single yarn. The specification of the binding or the like is arbitrary. For example, heat bonding is performed at a predetermined interval, or binding is performed with a binding member (preferably made of resin of the same material). Is exemplified.

The structure of the net structure is not particularly limited as long as it is in the form of a net, and any structure may be constituted by the single yarn.
For example, a single yarn may be a warp yarn and a weft yarn, arranged in a lattice with a predetermined mesh, and the intersections thereof may be heat-welded to form a net structure. The arrangement in this case is also arbitrary, such as those in which a weft is simply placed on a warp, or those in which a warp is further laid on a weft, or those in which a single yarn is further obliquely placed as desired, a warp and a weft Or a combination thereof.

In the present invention, the method for producing a three-dimensional molded article of the net structure is not particularly limited, but
For example, the following is exemplified. A flat net structure is prepared in which the intersections of the single yarns are heat-welded in advance, and then the net structure is heated and the softened one is pressed against a mold corresponding to a desired three-dimensional molded body. After deforming, cooling and molding.

[0016] A flat-shaped net structure in which the intersections of the single yarns are heat-welded is created. Thereafter, the net structure is held on or in a mold corresponding to a desired three-dimensional molded body. After heating, softening and deforming the object,
Cooling and molding. After forming a net structure in which the intersections of the single yarns are not heat-welded on or in a mold corresponding to a desired three-dimensional molded body, the net structure is heated and softened to perform heat welding at the intersections of the single yarns. A method in which the net structure is deformed and then cooled and molded.

The above-mentioned items can be appropriately applied to manual operation, manual operation and ready-made looms and knitting machines. Any known method can be applied to the method of heat welding or molding single yarns. And a hot press, a hot plate welding machine, an ultrasonic welding machine, a hot press and the like. Also,
The shape of the three-dimensional molded body is not particularly limited, and examples thereof include an arbitrary shape such as a cylindrical shape, a spherical shape, a polygonal prism shape, and a cloud-shaped prism shape.

The ratio of the continuous fiber reinforcing material used in the core material layer of the present invention is preferably in the range of 10 to 80% by weight, more preferably 30 to 70% by weight, based on the core material layer. If the continuous fiber reinforcing material in the core material layer is less than 10% by weight, the rigidity is too low, and if it exceeds 80% by weight, it becomes difficult to produce a single yarn.
As the continuous fiber reinforcement used in the present invention, known materials such as glass fiber, carbon fiber, metal fiber, and polymer fiber can be widely exemplified. These may be used alone or in combination of two or more. In terms of the reinforcing effect and the availability, inorganic fibers are preferred, and glass fibers are more preferred. As a continuous glass fiber bundle which is usually manufactured and marketed for resin reinforcement, glass roving can be mentioned. Usually its average fiber diameter is 4-30
μm, the number of bundles of filaments is 400 to 10,000, and the tex number is 300 to 20,000 g / km. Preferably, the average fiber diameter is 9 to 23 μm and the number of bundles is 1,000 to 6,000.

From the viewpoint of the reinforcing effect, the surface is preferably subjected to some treatment for imparting or improving the interfacial adhesion to the thermoplastic resin. For example, surface treatment with a surface treatment agent such as at least one of a silane coupling agent, a titanate coupling agent, a boron coupling agent, and an aluminate coupling agent may be mentioned.

The above continuous fiber reinforcing materials may be used alone or in combination of two or more. The resin to be impregnated in the fiber bundle is not particularly limited as long as it is a thermoplastic resin. Nevertheless, it is common to use crystalline resins, such as polyolefin-based resins, polyamide-based resins, and polyester-based resins for normal applications.

Among the above-mentioned crystalline thermoplastic resins, polyolefin resins are frequently used for ordinary applications from the viewpoint of properties and cost. Polyolefin resins include ethylene, propylene, 1-butene, 1-pentene, 1-
Hexene, 4-methyl-1-pentene, 1-octene, 1-decene and the like usually having about 2 to 10 carbon atoms of α-olefin, crystalline homopolymer or crystalline copolymer or these
This is a concept that includes compositions composed of two or more types. Among them, practically, polypropylene or a crystalline copolymer of propylene containing propylene as a main component and another α-olefin is rich in versatility. In the case of these polyolefin resins, from the viewpoint of the reinforcing effect, a modified polyolefin resin obtained by graft-reacting an unsaturated carboxylic acid or an anhydride thereof with a polyolefin resin, or a polyolefin resin and this modified polyolefin resin are used. Are preferred. For example, unsaturated carboxylic acids include acrylic acid, methacrylic acid, maleic acid, citraconic acid and mesaconic acid, and unsaturated carboxylic anhydrides include, for example, maleic anhydride and itaconic anhydride.

In the present invention, when such a modifier is used, an organic peroxide may be used in combination, if necessary. Examples of organic peroxides include, for example, 2,5-
Dimethyl (t-butylperoxy) hexane, 1,3-bis (t-
(Butyl-oxyisopropyl) benzene, dicumyl peroxide and benzoyl peroxide.

For applications where higher heat resistance is desired,
Various polyamide resins and polyester resins are suitable. Examples of the polyamide resin include 6-nylon, 6,6-nylon, 12-nylon, 6,10-nylon and the like. Examples of the polyester-based resin include polyethylene terephthalate (abbreviation: PET), polybutylene terephthalate (abbreviation: PBT), and the like.

The thermoplastic resin may contain various additives as required, for example, antioxidants, heat stabilizers, ultraviolet absorbers, resinous destruction inhibitors, antistatic agents, lubricants, plasticizers, release agents. Molding agents, flame retardants (flame retardants), flame retardant aids and crystallization accelerators (nucleating agents; crystallization agents) and one or more dyes and pigments can be blended. May be used in a form previously blended with the above-mentioned thermoplastic resin, or may be used in the form of a master batch.

When a resin skin layer is provided, if the thermoplastic resin of the core material layer and the resin of the resin skin layer are the same resin or a compatible resin, the bonding between the interfaces is reduced. It is preferable because it can be made strong. In order to produce the resin-made skin layer, for example, a method in which the resin is previously formed into a film shape, and then the film is laminated on the surface of the core material layer, a method in which a molten thermoplastic resin is coated on the surface of the core material layer, or the like Can be produced.

When the resin skin layer is formed by lamination, for example, first, a thermoplastic resin and, if necessary, a modifier and the like are mixed, supplied to an extruder, melt-kneaded, and formed. Film to form a film. Separately, for example, a molten thermoplastic resin is impregnated into a continuous fiber reinforcing material to form a core material layer. Then, while keeping the core material layer in a semi-molten state, the core material layer is laminated by laminating with a previously wound film. When bonding the core layer and the film, the core layer does not necessarily have to be in a semi-molten state, and the core layer may be cooled and solidified and then bonded to the film using an adhesive.

In the case where the resin skin layer is formed by coating, the surface of the core layer may be extruded and coated with a thermoplastic resin while the core layer is kept in a semi-molten state. After cooling and solidifying the core material layer,
The surface of the core material layer may be coated. 3 of the present invention
The three-dimensional molded body can be used as a protection or reinforcing material for home appliances and various products such as building materials such as pipes and pillars,
It can be used for various purposes such as snake baskets and fish reefs.

[0028]

EXAMPLES Next, the present invention will be described with reference to examples, but the present invention is not limited to these examples. Example 1 As a single yarn, a linear object having a thickness of 0.5 mm and a width of 14 mm made of a polypropylene resin containing 30% by weight of continuous glass fiber was prepared, and the linear objects were overlapped in a grid shape having a center-to-center distance of 50 mm. 65 with a thickness of 0.5 mm in a cooling press
A net-like structure of 0 mm × 650 mm was obtained. The net-like structure was heated in an oven and wound around a pipe with a diameter of 50 mm so that the latitudinal direction overlapped to form a pipe with a thickness of about 2 mm and a length of 650 mm.

Example 2 A wire having a thickness of 1.0 mm and a width of 7 mm made of continuous glass fiber reinforced polypropylene resin coated with a polyethylene resin having a thickness of 0.3 mm as a single yarn (glass concentration in the core material layer: 60% by weight) And make the distance between the centers of the linear objects 50
A net-like structure having a thickness of 1.0 mm and a size of 350 mm × 650 mm was obtained by stacking them in a grid pattern of mm and heating and cooling press. This net-like structure is heated in an oven and the
A 0 mm pipe was rolled so that the latitudinal directions overlap so as to be rolled to form a pipe having a thickness of about 2 mm and a length of 650 mm.

Comparative Example 1 0.5 mm thick and 10 m wide made of polypropylene resin
650 mm × with a thickness of 0.5 mm by heating and cooling press
A 650 mm net-like structure was obtained. This net-like structure is heated in an oven and wound around a pipe with a diameter of 50 mm so that the latitudinal directions overlap with each other.
An m-length pipe was formed.

Table 1 shows the results of measuring the pressure resistance of the pipe-like material obtained as described above. Pressure resistance: Place a pipe-like object on a hard board, and apply a linear pressure of 1k from above
Judgment was made based on the degree of collapse of the pipe-shaped material when a load of g / cm and 3 kg / cm was applied. ○: not crushed ×: crushed

[0032]

[Table 1]

In the comparative example in which the single yarn having no continuous fiber reinforcement was used as a constituent material of the net structure, the single yarn having the continuous fiber reinforcement could not withstand a linear pressure of 1 kg / cm. Example 1 used was able to withstand, and Example 2 using a single yarn having a resin skin layer provided a linear pressure of 3 kg / kg.
It can be seen that it can withstand up to cm.

[0034]

According to the present invention, since a single yarn having a thermoplastic resin containing a continuous fiber reinforcing material is used as a constituent material of a three-dimensional molded article of a net structure, rigidity, tensile strength, creep characteristics and the like are remarkably improved. It is possible to provide a three-dimensional molded body, and it can be used for various uses such as various reinforcing materials, snake cages and fish reefs which are lightweight, compact and easy to handle.

Claims (4)

[Claims] 1. A three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin, wherein a single yarn constituting the net structure is a continuous fiber drawn substantially parallel to its length direction. A three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin, comprising a tape or a linear core material layer in which a reinforcement is impregnated with a thermoplastic resin. 2. The three-dimensional molded article of a net structure made of a continuous fiber reinforced thermoplastic resin according to claim 1, wherein the single yarn has a resin skin layer formed on the surface of the core material layer. . 3. The resin skin layer has an average thickness of 0.0
The three-dimensional molded article of a net structure comprising a continuous fiber reinforced thermoplastic resin according to claim 2, wherein the thickness is 3 to 1.0 mm. 4. The single yarn according to claim 1, wherein at least one of the single yarns has a thickness of 0.2 to 2.0 mm.
3. A three-dimensional molded article of a net structure comprising the continuous fiber-reinforced thermoplastic resin according to any one of 3.