JPS6337907A - 補強熱可塑性シ−トの積層板の製造方法およびその製品 - Google Patents

補強熱可塑性シ−トの積層板の製造方法およびその製品

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Publication number
JPS6337907A
JPS6337907A JP62187468A JP18746887A JPS6337907A JP S6337907 A JPS6337907 A JP S6337907A JP 62187468 A JP62187468 A JP 62187468A JP 18746887 A JP18746887 A JP 18746887A JP S6337907 A JPS6337907 A JP S6337907A
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Prior art keywords
sheet material
laminate
materials
thermoplastic
weight
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JP2539228B2 (ja
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イアン・ステッドマン・ビッグス
ブロニスロー・ラドヴァン
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Wiggins Teape UK PLC
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Wiggins Teape UK PLC
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B7/02Physical, chemical or physicochemical properties
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
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    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51Elastic
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T156/1043Subsequent to assembly
    • Y10T156/1044Subsequent to assembly of parallel stacked sheets only
    • Y10T156/1048Subsequent to assembly of parallel stacked sheets only to form dished or receptacle-like product
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。

Description

【発明の詳細な説明】 産業上の利用分野 本発明は異なる不相溶性の熱可塑性シートから補強補熱
可塑性積層板を製造する方法およびこうして製造した製
品に関する。
従来の技術および 発明が解決しようとする問題点 本発明出願人による欧州特許出願第85300032.
1号(同公開公報第0148761号)には繊維補強プ
ラスチック材料シートの製造方法が開示されている。種
類を異にする熱可塑性材料から成るこの種のシートはあ
らかじめ縮収(con−solidate)されている
場合、積層が困難であることが知られている。しかしな
がら、欧州特許出願第85300031.3号(同公開
公報第0148760号)に記すごとく開始材料たるシ
ート材が非縮収となっている場合には積層板形成が可能
であり、または欧州特許出願第85300034゜7号
(同公開公報第0148763号)に記すごとく開始材
料シート材が縮収状態から膨張している場合には積層板
形成が可能になることが判明した。上記3つの欧州特許
出願に開示した内容は、以下本文中でも参照される。
問題点を解決するための手段 本発明によれば、補強熱可塑性補強シート材の積層板を
製造する方法が高い弾性率を有する20〜60重量%の
補強繊維と、他方のシート材中の熱可塑性材料と異なる
40〜80重量%の熱可塑性材料とから各々構成される
第1・第2多孔シート材を調製する工程と、該第1・第
2多孔シート材を縮収し接着して積層板を形成するため
該シート材を加熱し加圧する工程とから成る。シート材
の多孔質は非縮収状態の開始材料たるシート材に本来備
わっているものを利用してもよいし、縮収シート材を膨
張させることにより発生させてもよい。
好ましくは使用する繊維の大部分は長さが7〜5011
11、太さが13μ以下となるようにする。繊維は、分
離した単繊維とすると便利である。これら繊維は通常結
束切断した状態で人手されるが、これらをほぐしてシー
ト形成前に単繊維にする必要がある。
繊維が積層板の強度増加のため用いられる場合、分離ガ
ラス繊維は長さが約7m■より短くならないようにまた
は太さが13μを超えないようにする。
これは繊維が短いと可塑材料マトリックスを適切に補強
できず、太さがありすぎると同マトリックスの補強が効
果的でなくなるからである。またはガラス単繊維と少な
くとも同様の補強効果を有する他の種類の単繊維を用い
てもよい。
ここでいう高い弾性率とはシート材の弾性率に比べ実質
的に高い弾性率を意味する。この範鴫に入る繊維にはガ
ラス繊維、カーボン繊維、セラミック繊維の他に、ケブ
ラー(Kevlar)とノメックス(No■ex )の
商標名で市販されているアラミド繊維等の繊維があり、
また10,000メガパスカルを超える弾性率をもつい
ずれの繊維も包含する。
上述のごとく、シート材はまず縮収され次に積層形成に
先立って加熱し膨張させる。
また別の方法と゛して、非縮収シート材を形成し、積層
形成に先立って乾燥される。
熱可塑性材料として例えば、ポリエチレン、ポリプロピ
レン、ポリスチレン、アクリロニトリル/スチレン/ブ
タジェン、ポリエチレン テレフタレート、ポリブチレ
ン テレフタレート、ポリ塩化ビニールのいずれかをτ
型化および無可里化したもの、またはこれら材料同士の
または他のポリマー材料とのアロイまたはブレンドのい
ずれかから成る。その他好適な熱可塑性材料としてはポ
リフェニレン エーテル、ポリカーボネート、ポリエス
テルカーボネート、熱可塑性ポリエステル、ポリエステ
ルイミド、アクリロニトリル/ブチアクリレート/スチ
レンポリマー、非結晶ナイロン、ポリアリレン エーテ
ル ケトン、またはこれらの材料同士のまたは他のポリ
マー材料とのアロイまたはブレンドのいずれかがある。
実施例 以下に記す実施例では多孔性シート材(ASB)を欧州
特許出願第85300032.1号(同公開公報第01
48761号)に開示する方法に従って各々総重量20
00g/rrfで、25重量%のガラス繊維(太さ11
μ、長さ13+n)を含有し異なる熱可塑性材料に分散
させて成る。図面に示すごとくシート材(A)はアイ・
シー・アイ社(1,C,I Ltd、)のグレードGY
545Mのポリプロピレンで形成し、シート材(B)は
ジー・イーΦプラスチックス社(G、E、Plasti
cs Inc、 )のポリカーボネートとポリブチレン
テレフタレートとの熱可塑性70イであるXENOYで
形成した。
積層板は添付図面に示すごとく4種類の方法で作成した
。層と層の間の接着性は幅15mm長さ200mnの積
層片を切り取り、この積層片端部を反対方向へ離層(剥
離)か割れが生じるまで捩って主観的に判断した。
例 1(対照) 第1図に示すごとく、欧州特許出願第85300031
.3号(同公開公報第0148760号)に記す方法で
作成した未縮収乾燥シート材(A。
B)は個々に190℃および260℃でホットプレスし
、冷却して冷間縮収したシート材(1,2)を作成した
。冷間縮収シート材(1,2)を次に熱圧ブレス(3)
にて200ボンド/ 1nch2の圧力でホットプレス
した。シート材に接する熱圧ブレスの熱盤の温度は各々
170℃および250℃とした。こうして形成した積層
板(4)を冷却し、試験したところシート材間の接着性
は非常に小さいことがわかった。
例  2 第2図に示すごとく、あらかじめ縮収しているシート材
(A%B)を、欧州特許出願第85300034.7号
(同公開公報第0148763号)に記す方法にて加熱
膨張させ符号(5,8)で示すごとく通気性を有するよ
うにした。膨張シート材(5,6)に90℃で200ボ
ンド/ 1nch2の圧力をかけた。こうして作成した
積層板を冷却しシート材間の接着性を調べたところ第1
図に示す場合に比べより良好であることが判明した。
例  3 第3図に示すごとく、例1の開始材料と同種の材料から
成る未縮収シート材(A、B)を熱圧プレス(3)にて
200ボンド/ 1nch2の圧力で圧縮した。この時
の熱盤の温度は各々170℃と250℃とした。こうし
して作成した積層板を冷却して得たシート材間の接着性
は非常に良好であった。
例  4 ′X44図に示すごとく例1と同種の材料から成る未縮
収の乾燥シート材(A、B)を形成しホットプレスを行
なう前に共に乾燥させ、熱圧ブレスにより例3と同一の
処理を行なった。積層板の間の接着性は非常に良好であ
った。
例  5 第5図は例3の方法により形成した積層板(8)から製
品を製造する方法を示す。積層板(8)を熱圧ブレス内
の好適な加熱成形体(9)内に配し、200ポンド/I
nch2の圧力を加えて成形製品(11)を製造する。
使用材料により、積層板の仕上げすなわち成形工程は変
更してもよい。シート材(A)のガラス繊維含有率が比
較的低(、例えば25%である場合、成形製品の下面(
10)は滑らかな仕上りとなる。他方、同含有率が例え
ば60%と比較的高い場合には多孔表面が生じ、続く表
面層付着の際の定着部すなわち足掛かりとなる。
本発明は、従って片面に耐熱層を他面に安価な熱可塑性
材料から成る成形の容易な層を有する積層板の成形製品
を製造する方法を提供する。本発明は2層以上の積層板
を形成するために用いることもできる。例えば、3層積
層板で繊維補強ポリプロピレンの芯層と繊維補強ナイロ
ンの表面層を有するものを形成することもできる。
以下に示す例では重量が4000g/rrrでガラス繊
維を40%含有しているゲラスマット/ポリプロピレン
積層板から成る直径22CIlの円板(AZDELの商
標名で市販されている)をオーブンで7.5分間205
℃まで加熱し、皿状モールドにて2000ポンド/1n
ch2で所定材料に積層した。
例  6 積層板の第2シート材を欧州特許出願節8530003
1.3号(同公開公報第0148760号)に記載の方
法で長さ12mm、太さ11μのガラス繊維を30%と
アイ・シーφアイ社のMARANYL236Rの商標名
で市販され、ているナイロン6を70%とから作成した
3 000 g/rrrの多孔性非縮収シート材で構成
した。こうして作成した積層板は冷却時に良好な層間の
接着性を示した。
例  7 積層板の第2シート材は例6と同じもの、ただし熱可塑
性材料がジー・イー・プラスチックス社の商標名VAL
OXで市販のポリカーボネートとポリブチレンテレフタ
レートとの熱可塑性アロイを70%を含有する点で異な
るものを用いた。
こうして形成した積層板は冷却時には良好な層間の接着
性を示した。
【図面の簡単な説明】
第1図はシート材を結合させ接着性の小さい積層板を形
成する方法をは示す説明図、 第2図は本発明による積層板の製造方法を示す説明図、 第3図は本発明による別の製造方法を示す説明図、 第4図はさらに別の製造方法を示す説明図、第5図は本
発明により製造した積層板を用いて製品を製造する方法
を示す説明図である。 (A、B):開始材料シート材、 (1,2):縮収シート材、(3)】熱圧プレス、(5
,6)  ;膨張シート材。 特許出願人  ザ・ウイギンズ・ティーブ・グループΦ
リミテッド

Claims (1)

  1. 【特許請求の範囲】 〔1〕高い弾性率を有する20〜60重量%の補強繊維
    と、他方のシート材中の熱可塑性材料と異なる40〜8
    0重量%の熱可塑性材料とから各々構成される第1・第
    2多孔シート材を調製する工程と、該第1・第2多孔シ
    ート材を縮収し接着して積層板を形成するため該シート
    材を加熱し加圧する工程とから成る熱可塑性補強シート
    材積層板の製造方法。 〔2〕少なくとも一方のシート材が非縮収となっている
    、特許請求の範囲第1項記載の方法。 〔3〕少なくとも一方のシート材は縮収後膨張される、
    特許請求の範囲第1項記載の方法。 〔4〕前記補強繊維の大部分は長さが7〜50mmで、
    太さが13μ以下となっている、特許請求の範囲第1項
    から第3項のいずれか一項記載の方法。 〔5〕前記補強繊維は分離したガラス単繊維である、特
    許請求の範囲第1項から第4項のいずれか一項記載の方
    法。 〔6〕前記分離したガラス単繊維は長さが約7mm以上
    であるかまたは太さが13μ以下である、特許請求の範
    囲第5項記載の方法。 〔7〕前記シート材をまず縮収させ、次に積層板形成前
    に加熱し膨張させる、特許請求の範囲第3項から第6項
    のいずれか一項記載の方法。 〔8〕前記非縮収のシート材をいっしよに形成し乾燥さ
    せる、特許請求の範囲第1項記載の方法。 〔9〕前記熱可塑性材料はポリエチレン、ポリプロピレ
    ン、ポリスチレン、アクリロニトリル/スチレン/ブタ
    ジエン、ポリエチレンテレフタレート、ポリブチレンテ
    レフタレート、ポリ塩化ビニールのいずれかを可塑化お
    よび無可塑化にしたものまたはこれら材料同士のまたは
    他のポリマー材料とのアロイまたはブレンドのいずれか
    から成る、特許請求の範囲第1項から第8項のいずれか
    一項記載の方法。 〔10〕前記熱可塑性材料はポリフェニレン エーテル
    、ポリカーボネート、ポリエステルカーボネート、熱可
    塑性ポリエステル、ポリエステルイミド、アクリロニト
    リル/ブチアクリレート/スチレンポリマー、非結晶ナ
    イロン、ポリアリレンエーテルケトン、またはこれらの
    材料同士のまたは他のポリマー材料とのアロイまたはブ
    レンドのいずれかから成る、特許請求の範囲第1項から
    第9項のいずれか一項記載の方法。 〔11〕高い弾性率を有する20〜60重量%の補強繊
    維と、他方のシート材中の熱可塑性材料と異なる40〜
    80重量%の熱可塑性材料とから各々構成される第1・
    第2多孔シート材を調製する工程と、該第1・第2多孔
    シート材を縮収して接着して積層板を形成するため該シ
    ート材を加熱し加圧する工程とから成る方法によって製
    造した積層板を加熱成形して製造される製品。
JP62187468A 1986-07-31 1987-07-27 補強熱可塑性シ−トの積層板の製造方法およびその製品 Expired - Fee Related JP2539228B2 (ja)

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GB868618727A GB8618727D0 (en) 1986-07-31 1986-07-31 Thermoplastic sheets
GB8618727 1986-07-31

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JPS6337907A true JPS6337907A (ja) 1988-02-18
JP2539228B2 JP2539228B2 (ja) 1996-10-02

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FI873262A (fi) 1988-02-01
DK389587D0 (da) 1987-07-27
ATE86543T1 (de) 1993-03-15
US5639324A (en) 1997-06-17
CA1299480C (en) 1992-04-28
DE3784580T2 (de) 1993-06-17
JP2539228B2 (ja) 1996-10-02
AU607926B2 (en) 1991-03-21
DK164027C (da) 1992-09-28
GB8618727D0 (en) 1986-09-10
NO174770B (no) 1994-03-28
NO873138D0 (no) 1987-07-27
DK389587A (da) 1988-02-01
FI92303C (fi) 1994-10-25
FI92303B (fi) 1994-07-15
US4957805A (en) 1990-09-18
NO873138L (no) 1988-02-01
IE872027L (en) 1988-01-31
KR880001431A (ko) 1988-04-23
PT85416A (pt) 1988-07-29
IE59731B1 (en) 1994-03-23
DK164027B (da) 1992-05-04
DE3784580D1 (de) 1993-04-15
BR8703883A (pt) 1988-03-29
EP0255315B1 (en) 1993-03-10
PT85416B (pt) 1994-11-30
EP0255315A3 (en) 1989-11-29
ZA875503B (en) 1988-02-01
NO174770C (no) 1994-07-06
FI873262A0 (fi) 1987-07-27
AU7614287A (en) 1988-02-04
ES2053546T3 (es) 1994-08-01
EP0255315A2 (en) 1988-02-03
KR950012800B1 (ko) 1995-10-21

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