KR20230155119A - Fiber reinforced plastic composite from recycled plastic and Method for manufacturing the composite - Google Patents

Abstract

The fiber-reinforced plastic composite using recycled plastic of the embodiment is composed of a recycled long fiber composite sheet and a continuous fiber composite laminated on the recycled long fiber composite sheet, and the recycled long fiber composite sheet is a mixture of thermoplastic resin and glass fiber. It is a sheet, and the thermoplastic resin is characterized in that it is made of a mixture of recycled polypropylene and new (not recycled) polypropylene.
And, the mixing ratio of recycled polypropylene, new polypropylene, and glass fiber constituting the recycled long fiber composite sheet is such that the recycled polypropylene is mixed so that the weight ranges from 20 to 40%, and the new polypropylene is mixed such that the weight ranges from 60 to 40%. It is characterized by being mixed to have a weight within the 80% range.

Description

Fiber reinforced plastic composite from recycled plastic and Method for manufacturing the composite}

The present invention relates to a method of producing a high-strength fiber-reinforced plastic composite using recycled plastic, and to a composite produced by the method.

Recently, the use of plastic materials in automobile parts has been increasing. In particular, polypropylene (PP) resin is replacing ABS or nylon resin, which was previously widely used as a material for automobile parts, due to its low price, low specific gravity, and easy processing. An example of this is PP composite material used for automobile interior parts.

In general, the material used for automobile interior parts is PP resin with various types of fillers added to enhance impact resistance and strength. Recently, the use of parts molded from thermoplastic polymer composites containing long fiber-based fillers with a fiber length of 3 mm or more within the composite material has been increasing to improve both impact resistance and tensile strength.

Examples of the long fiber filler include glass fiber, synthetic fiber, and natural fiber.

Accordingly, research is being actively conducted on technologies that can recycle polymer composite materials containing long-fiber fillers. However, when applying conventional recycling technology for plastic materials, polymer composite materials containing long-fiber fillers are difficult to recycle. The reason is that in the cleaning process for recycling, the cleaning water penetrates and is absorbed into the waste plastic along the interface between the long fiber filler of the waste plastic and the matrix resin, resulting in the recycling manufactured through the next process, extrusion and cooling. This is because the physical properties of polymer materials appear to deteriorate overall. Accordingly, in the current plastic recycling industry, only polymer composite materials to which existing recycling technology can be applied are separately separated and recycled, and polymer composite materials containing long fiber-based fillers above a certain level are classified as waste and disposed of in landfill or incineration. It is happening.

Therefore, for the recycling of waste plastics containing long-fiber fillers, the deterioration of the resin material during the use process, contamination due to the mixing of foreign substances during the recycling process, mixing of resins of different materials, and moisture absorption and physical and chemical deterioration. There is a need for a recycling method for waste plastic that can compensate for the decline in physical properties.

(Patent Document 1) KR10-0761944 B

The present invention seeks to propose an apparatus and method for manufacturing high-strength fiber-reinforced plastic composites through a manufacturing process of laminating and lamination of long-fiber composite sheets manufactured using recycled plastic and continuous fiber composites with excellent physical properties. By way of example, it is possible to produce a composite material with excellent physical properties at a low cost.

The fiber-reinforced plastic composite using recycled plastic of the embodiment is composed of a recycled long fiber composite sheet and a continuous fiber composite laminated on the recycled long fiber composite sheet, and the recycled long fiber composite sheet is a mixture of thermoplastic resin and glass fiber. It is a sheet, and the thermoplastic resin is characterized in that it is made of a mixture of recycled polypropylene and new (not recycled) polypropylene.

And, the mixing ratio of recycled polypropylene, new polypropylene, and glass fiber constituting the recycled long fiber composite sheet is such that the recycled polypropylene is mixed so that the weight ranges from 20 to 40%, and the new polypropylene is mixed such that the weight ranges from 60 to 40%. It is characterized by being mixed to have a weight within the 80% range.

In addition, the continuous fiber composite material is characterized as a continuous fiber composite material having a structure in which fibers are arranged in a first direction.

In addition, the continuous fiber composite material is characterized in that it consists of two continuous fiber composite materials having a structure in which fibers are arranged in a first direction, and a continuous fiber composite material having a structure in which fibers are arranged in a second direction, which is a direction perpendicular to the first direction. do.

Meanwhile, in the method of manufacturing a fiber-reinforced plastic composite using recycled plastic of an embodiment, thermoplastic resin and roving glass fiber mixed with recycled and new material at a preset weight ratio are cut and mixed in an extruder and extruded onto strands. A step of producing a sheet by cooling and compressing the thermoplastic resin and glass fiber extruded onto the strand by a cooling roll, and unwinding the continuous fiber laminate roll disposed on the sheet, and forming the sheet by a lamination roll. A step of laminating a continuous fiber composite material on a sheet, cutting the sheet that has passed through the lamination roll, and the continuous fiber composite material laminated on the sheet, wherein the thermoplastic resin is made of recycled polypropylene and new polypropylene. The mixing ratio of the recycled polypropylene, new polypropylene, and glass fiber is such that the recycled polypropylene is mixed to have a weight in the range of 20 to 40%, and the new polypropylene is mixed to have a weight in the range of 60 to 80%. The continuous fiber composite material wound around the continuous fiber laminate roll includes a continuous fiber composite material having a structure in which fibers are arranged in a first direction, and a continuous fiber composite material having a structure in which fibers are arranged in a second direction, which is a direction perpendicular to the first direction. It is characterized by a structure in which fiber composite materials are laminated.

According to an embodiment of the present invention, there is an advantage in providing a high-strength fiber-reinforced plastic composite through a lamination and laminating process of a long-fiber composite sheet using recycled plastic with excellent price and formability and a continuous fiber composite with excellent physical properties. .

Figure 1 is a diagram for explaining a method of manufacturing a fiber-reinforced plastic composite using recycled plastic according to an embodiment of the present invention.
Figure 2 is a diagram showing an example of a 1-ply continuous fiber composite.
Figure 3 is a diagram illustrating a fiber-reinforced plastic composite material in which continuous fiber composite material with fibers arranged in a first direction is laminated on a recycled long-fiber composite sheet.
Figure 4 is a diagram showing an example of a two-ply continuous fiber composite.
Figure 5 is a diagram illustrating a fiber-reinforced plastic composite material in which a continuous fiber composite material with fibers arranged in a first direction and a continuous fiber composite material with fibers arranged in a second direction are sequentially laminated on a recycled long fiber composite sheet.

Hereinafter, embodiments disclosed in the present specification will be described in detail with reference to the attached drawings. However, identical or similar components will be assigned the same reference numbers regardless of reference numerals, and duplicate descriptions thereof will be omitted. The suffixes “module” and “part” for components used in the following description are given or used interchangeably only for the ease of preparing the specification, and do not have distinct meanings or roles in themselves. Additionally, in describing the embodiments disclosed in this specification, if it is determined that detailed descriptions of related known technologies may obscure the gist of the embodiments disclosed in this specification, the detailed descriptions will be omitted. In addition, the attached drawings are only for easy understanding of the embodiments disclosed in this specification, and the technical idea disclosed in this specification is not limited by the attached drawings, and all changes included in the spirit and technical scope of the present invention are not limited. , should be understood to include equivalents or substitutes.

Terms containing ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by the terms. The above terms are used only for the purpose of distinguishing one component from another.

When a component is said to be "connected" or "connected" to another component, it is understood that it may be directly connected to or connected to the other component, but that other components may exist in between. It should be. On the other hand, when it is mentioned that a component is “directly connected” or “directly connected” to another component, it should be understood that there are no other components in between.

Singular expressions include plural expressions unless the context clearly dictates otherwise.

In this application, terms such as “comprise” or “have” are intended to designate the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, but are not intended to indicate the presence of one or more other features. It should be understood that this does not exclude in advance the possibility of the existence or addition of elements, numbers, steps, operations, components, parts, or combinations thereof.

Figure 1 is a diagram for explaining a method of manufacturing a fiber-reinforced plastic composite using recycled plastic according to an embodiment of the present invention.

Referring to FIG. 1, for manufacturing the fiber-reinforced plastic composite 100 of this embodiment, a recycled long fiber composite sheet 110 and a continuous fiber composite 120 laminated on the recycled long fiber composite sheet 110. Let's explain it by focusing on .

The long fiber composite sheet forming the base layer of the fiber-reinforced plastic composite material of the embodiment is a thermoplastic resin (1b) in which recycled and new materials are mixed at a preset weight ratio and glass fibers in a roving state are cut and mixed in an extruder (1b). and is extruded onto the strand (1c).

Then, the thermoplastic resin and glass fiber extruded onto the strand 1c are cooled and compressed by the cooling roll 4 to produce a sheet 1d, and on the manufactured sheet 1d, that is, a recycled long fiber composite sheet. In order to laminate continuous fibers in one or two layers, a continuous fiber laminate roll (2a) is placed on the sheet (1d) at the lamination starting point.

Then, as the continuous fiber laminate roll (2a) located at the starting point unwinds and rotates, the continuous fiber composite material is spread flat in the 0 degree direction and inserted into the lamination roll (5).

The continuous fiber composite material inserted into the lamination roll (5) is stacked/laminated on the first layer of long fiber composite sheet (1d). Next, the two- or three-layer composite material that has passed through the lamination roll (5) is cut to a certain length.

In particular, the continuous fiber wound on the continuous fiber laminate roll 2a is composed of only one ply of a continuous fiber composite material having a structure in which fibers are arranged in a first direction, which is a specific direction, or a continuous fiber composite material having a structure in which fibers are arranged in a first direction, which is a specific direction. It may be composed of a two-ply composite material in which a fiber composite material and a continuous fiber composite material having a structure in which fibers are arranged in a second direction perpendicular to the first direction are laminated, in which case the two-ply continuous fiber composite material is the continuous fiber laminate. When wound on the roll 2a, the composite material laminated through the lamination roll 5 may be composed of a single-layer long fiber composite sheet and a two-layer continuous fiber composite material thereon.

The recycled long fiber composite sheet 110 is a sheet containing a mixture of thermoplastic resin and glass fiber, and the thermoplastic resin uses a mixture of recycled polypropylene and new (not recycled) polypropylene.

And, continuous fiber composites can be manufactured through a drawing process of glass fiber or carbon fiber.

In particular, in the recycled long fiber composite sheet, the mixing ratio of recycled polypropylene and new polypropylene, that is, the weight ratio, is that recycled polypropylene accounts for 20 to 40% of the weight, and the remaining new polypropylene accounts for 60 to 80%. It is desirable to take up the weight of the scope.

Table 1 below shows the results of testing the tensile strength, flexural strength, flexural modulus, and impact strength of six types of long fiber composites composed of different mixing ratios of new polypropylene and recycled polypropylene.

Excluding glass fiber, it is desirable for recycled polypropylene to account for a maximum of 40% of the weight, and for new polypropylene not to exceed 60% of the weight. As can be seen in Table 1, the weight of recycled polypropylene is This is because when the weight accounts for more than 50%, the physical properties of tensile strength, flexural strength, flexural modulus, and impact strength all drastically decrease.

Therefore, in the present invention, in the case of recycled polypropylene, it is preferable that the weight ratio of the long fiber complex is mixed only up to 40%, and in the case of new polypropylene, it is preferable that it is mixed only up to 60%.

In addition, the continuous fiber composite material 120 is made by impregnating a thermoplastic resin into continuous fibers showing fibers arranged in a preset one direction.

First, according to the embodiment, thermoplastic resin made of a mixture of recycled and new materials and glass fiber roved in the roving machine 20 are cut and mixed together in the extruder 10.

Then, after cutting and mixing from the extruder 10, the mixture is extruded onto the recycled long fiber composite strand 30.

In addition, a process for cooling the regenerated long fiber composite is performed by a pair of cooling rolls 1 disposed at predetermined intervals above and below, and the regenerated long fiber composite cooled by the cooling roll is cooled. It is formed into a recycled long fiber composite sheet 110.

Then, a process for laminating the continuous fiber composite 120 on the recycled long fiber composite sheet 110 is performed, and the continuous fiber composite 120 laminated in one or two layers is formed by the recycled long fiber composite sheet ( 110), and Figure 1 shows a continuous fiber composite roll 40 in which one layer of continuous fiber composite material is rolled. According to another embodiment, a two-ply laminated continuous fiber composite may be wound around the continuous fiber composite roll 40. In this case, two layers of continuous fiber composite material may be wound on the recycled long fiber composite sheet 110. are laminated.

Figure 2 shows an example of a single-ply continuous fiber composite material, which is a continuous fiber composite material 120 having a structure in which fibers are arranged in a specific direction (first direction). And, Figure 4 shows an example of a two-ply continuous fiber composite material, which has a structure in which a composite material with fibers arranged in a first direction and a composite material with fibers arranged in a second direction perpendicular to the first direction are laminated thereon. It is a fiber composite (120,130).

The continuous fiber composite material supplied through the continuous fiber composite roll 40 is divided into two lamination rolls 2, each disposed on the upper and lower sides of the recycled long fiber composite sheet 110. ) is laminated on the

That is, the long fiber composite sheet 110 made of a sheet is inserted by hanging at the bottom of the lamination roll 5 through a belt, and the continuous fiber composite material 120 laminated on the upper surface is in the form of a continuous fiber composite roll 40. It is placed at the starting point of the lamination machine.

In detail, the continuous fiber composite roll 40 hanging at the starting point is unwinded and spread flat in the 0-degree direction and inserted into the lamination roll 2, and the continuous fiber composite inserted into the lamination roll is one layer of recycled long fiber composite sheet. It is laminated on (110).

Next, the two-ply composite laminate that has passed through the lamination roll (2) is cut to a certain length.

Meanwhile, as described above, two layers of continuous fiber composite material are wound around the continuous fiber composite roll 40, and after lamination using a lamination roll, a 3-layer composite laminate is formed.

Figure 3 shows a fiber-reinforced plastic composite in which a continuous fiber composite 120 with fibers arranged in a first direction is laminated on a recycled long fiber composite sheet 110, and Figure 5 shows a continuous fiber composite with fibers arranged in a first direction. A fiber-reinforced plastic composite material is shown in which 120 and a continuous fiber composite material 130 with fibers arranged in the second direction are sequentially stacked on a recycled long fiber composite sheet 110.

Table 2 below shows the results of testing the physical properties of a fiber-reinforced plastic composite material consisting of a 1-ply continuous fiber composite sheet and a 2-ply continuous fiber composite sheet laminated on a recycled long fiber composite sheet according to this example. am.

Long fiber composites (L1, L5, where L1 and L2 test materials are the same as those used in Table 1), continuous fiber composites (C1 for 1-ply formation, C2 for 2-ply formation), and blend composition (L5+ This is the result table of testing each physical property in the case of C1, L5+C2).

As a result of the test, when 1 or 2 layers of continuous fiber composite are laminated on a regenerated long fiber composite using a maximum of 40% weight of recycled polypropylene mixed into the long fiber composite (mixed composition), only new polypropylene is 70%. (When recycled polypropylene is not used) It can be confirmed that a composite material with excellent physical properties can be manufactured compared to the long fiber composite material (L1) used.

Claims (5)

A recycled long fiber composite sheet,
It is made of a continuous fiber composite laminated on the recycled long fiber composite sheet,
The recycled long fiber composite sheet is a sheet containing a mixture of thermoplastic resin and glass fiber,
The thermoplastic resin is a fiber-reinforced plastic composite material using recycled plastic, characterized in that it is made of a mixture of recycled polypropylene and new (not recycled) polypropylene. According to claim 1,
The mixing ratio of recycled polypropylene, new polypropylene, and glass fiber constituting the recycled long fiber composite sheet is such that the recycled polypropylene is mixed to have a weight in the range of 20 to 40%, and the new polypropylene is 60 to 80%. A fiber-reinforced plastic composite using recycled plastic, characterized in that it is mixed to have a weight within a range. According to claim 2,
The continuous fiber composite is a fiber-reinforced plastic composite using recycled plastic, characterized in that the continuous fiber composite has a structure in which fibers are arranged in a first direction. According to claim 2,
The continuous fiber composite material is a continuous fiber composite material having a structure in which fibers are arranged in a first direction, and a continuous fiber composite material having a structure in which fibers are arranged in a second direction perpendicular to the first direction. Fiber-reinforced plastic composite using plastic. A thermoplastic resin in which recycled and new materials are mixed at a preset weight ratio and glass fibers in a roving state are cut and mixed in an extruder and extruded onto strands;
Manufacturing the thermoplastic resin and glass fibers extruded onto the strands into a sheet by cooling and compressing them with a cooling roll;
Unwinding the continuous fiber laminate roll disposed on the sheet and laminating the continuous fiber composite material on the sheet by a lamination roll;
Comprising the step of cutting the sheet that has passed through the lamination roll and the continuous fiber composite material laminated on the sheet,
The thermoplastic resin is made of recycled polypropylene and new polypropylene, and the mixing ratio of the recycled polypropylene, new polypropylene, and glass fiber is such that the recycled polypropylene has a weight in the range of 20 to 40%, and the new polypropylene is mixed. Propylene is mixed to have a weight in the range of 60 to 80%,
The continuous fiber composite material wound around the continuous fiber laminate roll includes a continuous fiber composite material having a structure in which fibers are arranged in a first direction, and a continuous fiber composite material having a structure in which fibers are arranged in a second direction, which is a direction perpendicular to the first direction. A method of manufacturing a fiber-reinforced plastic composite using recycled plastic, characterized in that it consists of a laminated structure.

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