TW202006024A - CFRP sheet, laminated body using CFRP sheet, and CFRP sheet production method - Google Patents

Abstract

To provide a CFRP sheet that is not only excellent in terms of mechanical strength such as tensile strength, but also excellent in terms of visible surface design. This CFRP sheet is constituted by forming a transparent resin layer on the outer side of a surface layer from a CFRP layer.

Description

CFRP sheet, laminate using CFRP sheet, and method of manufacturing CFRP sheet

The present invention relates to improvement of CFRP sheets, in particular, to CFRP sheets excellent in design and design, laminates using the same, and an efficient manufacturing method of the aforementioned CFRP sheets.

In recent years, carbon fiber reinforced plastic (CFRP) composed of carbon fiber reinforced fiber material and matrix resin has been used in various applications due to its excellent functionality. In addition, as CFRP sheets, those in which continuous fibrous carbon fiber bundles are aligned in the vertical and horizontal directions or those in which the carbon fiber bundles are flat-woven and impregnated with matrix resin are widely known.

However, regarding the above-mentioned conventional CFRP sheet, when the CFRP sheet is formed into any shape by hot-pressing, the continuous fibrous carbon fiber bundle system extending throughout the entire sheet becomes the main reason for hindering the followability of the pressurized mold. As a result, the shapeability is deteriorated, and as a result, there is a disadvantage of limiting the shape to be formed.

Therefore, in the past, a UD sheet in which carbon fiber bundles aligned in the longitudinal direction are integrated by a matrix resin has been developed, finely cut into long strips, and the cut long UD sheet is formed in a secondary element. They are aligned side by side and integrated by hot pressing to form a thin CFRP sheet (for example, refer to Patent Document 1).

However, the above-mentioned conventional CFRP sheet has an appearance in which only long (rectangular) UD sheets are juxtaposed on the surface. Since there is no large difference in the shape of each UD sheet, the appearance of the surface tends to be a monotonous design. Therefore, CFRP sheets are hardly used in applications such as decorative sheets requiring design. [Prior Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open No. 2016-27956

[Problems to be solved by the invention]

The present invention has been completed in view of the above-mentioned problems, and its object is to provide a CFRP sheet that is not only excellent in mechanical strength such as tensile strength, but also excellent in design of the design of the visible surface, a laminate using the same, and the efficiency of the CFRP sheet Manufacturing method. [Means to solve the problem]

With reference to the drawings, the means adopted by the inventor to solve the above-mentioned problems will be described as follows.

That is, the present invention is characterized in that a transparent resin layer C is formed outside the surface layer of the CFRP layer S to form a CFRP sheet, and the continuous fibrous carbon fibers F·F... are aligned in the longitudinal direction. The majority of UD sheets integrated by matrix resin M are integrated in a state in which the fiber directions of each sheet are randomly aligned, and the sheets are superimposed on each other in the state of being side by side in the direction of the two-dimensional element. The CFRP layer S is formed next by the matrix resin M. On the other hand, the UD sheet P·Q... with respect to the back layer or the intermediate layer of the CFRP layer S is rectangular in shape and contains an average thickness that is greater than that of the back layer or the intermediate layer. The UD sheet Q is smaller, and at least a part of it is deformed into a non-rectangular sheet to constitute the UD sheet P·P... of the surface layer.

In addition, in this specification, the "non-rectangular shape" refers to the difference between the maximum value and the minimum value of the width dimension of the UD sheet (the dimension perpendicular to the longitudinal direction of the carbon fiber) becomes the maximum width dimension 10% or more of the value, or the difference between the maximum value and the minimum value of the length dimension of the UD sheet (parallel dimension relative to the longitudinal direction of the carbon fiber) becomes 10% or more of the maximum value of the length dimension .

In addition, the present invention may also be a CFRP sheet formed by forming a transparent resin layer C on the outer side of the surface layer of the CFRP layer S, wherein the CFRP layer S is arranged by aligning continuous fibrous carbon fibers F·F... in the longitudinal direction In the state, the majority of UD sheets integrated by matrix resin M are integrated in a state where the fiber direction of each sheet is randomly aligned, and the sheets are superimposed on each other in the state of being side by side in the direction of the second element It is formed by the matrix resin M. On the other hand, the UD sheet P·Q of the surface layer and the back layer of the CFRP layer S includes a sheet deformed into a non-rectangular shape.

In addition, in the present invention, the ratio of the deformed non-rectangular UD sheet P in the surface layer of the CFRP layer S is set to 30% or more (preferably 50% or more), which can form a unique design design CFRP sheet with excellent properties.

On the other hand, in the present invention, by setting the average area of each of the UD sheets P in the surface layer of the CFRP layer S to be larger than the average area of the UD sheet Q of the back layer or the intermediate layer, it can be increased The deformation of the shape of the UD sheet P of the large surface layer improves the design effect.

Also, in the present invention, the ratio of the loosened portion L by partially separating the parallel carbon fibers in the UD sheet P of the surface layer of the CFRP layer S is set to be more than the UD sheet Q of the back layer or the intermediate layer Large, can increase the deformation of the shape of the UD sheet P of the surface layer, and improve the design effect.

In addition, in the present invention, since the matrix resin in the CFRP layer S is a thermoplastic resin having adhesion to the thermoplastic resin of the transparent resin layer C, the easy surface layer can be easily released when the transparent resin layer C is formed UD flake P.

In addition, in the present invention, by integrating the above-mentioned CFRP sheet laminate on the surface of the same material or different materials, it is possible to construct a laminate having a unique appearance and excellent design.

In addition, in the present invention, as the method for manufacturing the CFRP sheet, it may be adopted that the UD sheet and the resin film as the material of the transparent resin layer which are side by side in the direction of the two-dimensional element are rolled and temporarily adhered , Or by applying a molten resin as the material of the transparent resin layer on a plurality of UD sheets side by side in the two-dimensional direction, and hot pressing, to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated, by The method of further hot pressing the intermediate sheet to deform the UD sheet of the surface layer.

In addition, in the above-mentioned manufacturing method, it is preferable that the pressure applied to the hot pressing of the intermediate sheet material is higher than the pressure applied to the roll forming when the UD sheet and the resin film are temporarily adhered or the UD sheet coated with the molten resin The pressure of hot pressing is greater.

On the other hand, in the present invention, instead of the above-mentioned manufacturing method, in the manufacturing method of the CFRP sheet, a continuous-fiber-shaped carbon fiber and a thermoplastic resin are formed by rolling and then carbon fibers are bonded to each other to produce a UD sheet. At the same time, the UD sheet is cut into a rectangular shape, and the produced UD sheet is arranged on the resin film which is the material of the transparent resin layer in the direction of the secondary element, or on a plurality of UD sheets arranged side by side in the direction of the secondary element A method of applying molten resin as a material of a transparent resin layer and performing heat compression molding to deform the UD sheet of the surface layer.

In addition, in the above-described manufacturing method, it is preferable that the pressure for heating and compression molding of the UD sheet of the resin film or the pressure of heating and compression molding for the UD sheet coated with the molten resin is higher than that of the roller when the UD sheet is produced Pressing pressure is greater.

In addition, in the present invention, in the above-described manufacturing method, in order to improve the design of the surface design, it is preferable to make the basis weight of the resin film 5% or more with respect to the basis weight of the entire UD sheet. [Effect of invention]

In the present invention, a plurality of UD sheets are arranged in a state in which the fiber directions of each sheet are randomly aligned, and the sheets are superimposed on each other, in a state of being side by side in the direction of the two-dimensional element, and then CFRP sheets are produced, At the same time, by including the UD sheet deformed into a non-rectangular shape in the surface layer, a unique appearance can be given to the surface of the sheet.

Furthermore, in the present invention, since the rectangular UD sheet having a larger thickness and a uniform shape than the UD sheet of the surface layer constitutes the back layer or the intermediate layer of the CFRP sheet, the tensile strength of the CFRP sheet is not significantly impaired For considerations, both design and mechanical strength can be considered.

Therefore, according to the present invention, it is possible to provide a CFRP sheet that can be used without any problem even as a reinforcing sheet or the like, and can be applied even as a surface sheet or the like that requires design, so the practical utility value of the present invention is quite high.

[Forms for carrying out the invention] "First Embodiment"

The first embodiment of the present invention will be described below based on FIGS. 1 to 3. In the figure, the symbol S indicates the sheet body, and the symbol M indicates the matrix resin. Moreover, the symbol indicated by the symbol P is the UD sheet of the surface layer, and the symbol indicated by the symbol Q is the UD sheet of the inner layer. In addition, the symbol F indicates carbon fiber.

"Composition of CFRP sheet" [1] Basic composition of CFRP sheet First, in this embodiment, as shown in FIG. 1, a CFRP layer S is formed, and a transparent resin layer C is formed outside the surface layer on the visible side to form a sheet body. In addition, as shown in FIG. 2(a)(b)(c), the CFRP layer S is composed of UD sheets P·Q arranged in parallel in the two-dimensional direction in such a manner that the sheets are superposed on each other. The carbon fiber material of Q is randomly aligned (the direction of the fiber direction of the UD sheet becomes side by side in a scattered manner), which is formed by the matrix resin M being then integrated.

In addition, in the UD sheet P·Q of the CFRP layer S, as shown in FIG. 3(a)(b), a state in which continuous fibrous carbon fibers F·F... are aligned in the longitudinal direction is used. Resin M continues to be integrated. In addition, the back layer or the intermediate layer that becomes the non-visible surface of the CFRP layer S is formed by arranging rectangular UD sheets Q·Q... shown in FIG. 3(b). On the other hand, the surface of the CFRP layer S The layer is formed by arranging UD sheets P·P... whose average thickness is smaller than the UD sheet Q of the back layer or the intermediate layer as shown in FIG. 3(a), and includes at least a part of the sheet deformed into a non-rectangular shape.

By constructing the sheet body as described above, it is possible to secure the mechanical strength of the CFRP layer S by the UD sheet Q·Q... with a relatively large thickness of the back layer or the intermediate layer, and the surface with a relatively small thickness and an uneven shape The layered UD sheet P·P... gives a unique appearance to the sheet body as shown in Fig. 2(b). In addition, the transparent resin layer C formed outside the surface layer of the CFRP layer S can improve the smoothness of the surface of the sheet body, and can also give the CFRP layer S a protective effect or an optical visual effect.

[2] About CFRP layer carbon fiber material Next, each constituent element of the aforementioned sheet body will be described. First, regarding the continuous fibrous carbon fiber F constituting the UD sheet P·Q of the CFRP layer S, in the present embodiment, a carbon fiber bundle (filament) in which filaments are bundled into a strand is used. In this embodiment, PAN-based carbon fibers are used as the carbon fibers F, but pitch-based carbon fibers may also be used. In addition, the number of filaments constituting the carbon fiber bundle can be arbitrarily changed according to strength and the like.

[3] About the matrix resin of the CFRP layer, In addition, regarding the matrix resin M of the CFRP layer S, a polyamide resin (nylon resin) is used in the present embodiment, but it is not limited thereto, and other thermoplastic resins (acrylic acid) impregnated with carbon fiber materials may also be used. Resin or polyester, polyolefin, polystyrene, polycarbonate, ABS resin, polyetherimide, fluorine-based resin, polyphenylene sulfide, etc.) or thermosetting resin.

In addition, when the CFRP layer S and the transparent resin layer C are integrated by hot pressing (details will be described later), the matrix resin in the CFRP layer S uses a thermoplastic resin having adhesion to the thermoplastic resin of the transparent resin layer C. The UD sheet P of the surface layer can be easily loosened during hot pressing.

[4] About the shape of the UD sheet [4-1] The shape of the UD sheet of the surface layer, and about the UD sheet P of the surface layer of the CFRP layer S described above, in order to improve the design effect of the design in this embodiment, the deformation is changed to non- The ratio of the rectangular UD sheet P becomes 30% or more. Also, regarding the non-rectangular UD sheet P, as shown in FIG. 3(a), the difference between the maximum value X ₁ and the minimum value X ₂ of the length of the UD sheet is 10% or more of the maximum value X ₁ , or The difference between the maximum value Y ₁ and the minimum value Y ₂ of the width dimension is 10% or more of the maximum value Y ₁ .

In addition, regarding the thickness of the UD sheet P of the above-mentioned surface layer, in this embodiment, the shape of the UD sheet P of the surface layer is deformed so that the average thickness becomes the average thickness of the UD sheet Q of the back layer or the intermediate layer About half. In this embodiment, the average value of the maximum value Y ₁ of the width of the UD sheet P is regarded as the average width, and the average width is 1.5 times or more the average width of the UD sheet Q of the back layer or the intermediate layer. . Furthermore, in the present embodiment, the average area of each of the UD sheets P of the surface layer is larger than the average area of the UD sheets Q of the inner layer.

In addition, in this embodiment, in order to increase the deformation of the shape of the UD sheet P of the surface layer, the average width of the UD sheet P of the surface layer is larger than the average width of the UD sheet Q of the back layer or the intermediate layer. In addition, for the same purpose, the ratio of the unclamped portion L that partially separates the juxtaposed carbon fibers F of the UD sheet P of the surface layer from each other is larger than that of the UD sheet Q of the back layer or the intermediate layer.

[4-2] Shape of UD sheet on the back layer or middle layer Further, regarding the UD sheet Q of the back layer or the intermediate layer of the CFRP layer S, in this embodiment, the width W5 mm×the length L20 mm is used. However, considering the strength or the formability, the width W2 mm to 20 mm (preferably It is a rectangular shape with a length of 5 mm to 10 mm), a length L of 5 mm to 70 mm (preferably 10 mm to 30 mm), and a ratio of width W to length L of 1:1 to 1:6. In this specification, the direction along the longitudinal direction of the carbon fiber F is regarded as the longitudinal direction of the UD sheet P, and the direction perpendicular thereto is regarded as the width direction. In addition, the thickness of the UD sheet Q of the back layer or the intermediate layer is preferably in the range of 40 μm to 100 μm.

[4-3] Number of overlapping UD sheets In addition, in the present embodiment, the average number of UD sheets P and Q stacked in the CFRP layer S in the thickness direction is designed to be in the range of 5.0 sheets to 8.0 sheets, but any sheet can be used according to the strength of the sheet body Number design. Further, the thickness of the CFRP layer S is preferably designed in the range of 0.3 mm to 1.0 mm, but it may be formed in a thicker plate shape.

[5] About the surface layer, back layer and intermediate layer of CFRP layer The surface layer that becomes the visible surface of the CFRP layer S is formed only on one side of the sheet body in this embodiment, but it may also be formed on both sides of the sheet body. At that time, the back layer of the CFRP layer S did not exist, but was only composed of the surface layer and the middle layer. In addition, when the thickness of the CFRP layer S is very small, there are cases where the intermediate layer does not exist, and only the surface layer and the back layer are formed.

[6] About transparent resin layer [6-1] Material of transparent resin layer In addition, regarding the material of the above-mentioned transparent resin layer C, a polyamide resin is used in the present embodiment, but it is not limited thereto, and other thermoplastic resins (acrylic resin or PET, poly Ethylene, polystyrene, polycarbonate, ABS resin, polyetherimide, fluorine-based resin, polyphenylene sulfide, etc.) or thermosetting resin. In addition, the transparent resin layer C is not only colorless and transparent, but also includes some colored translucent ones.

[6-2] Thickness of transparent resin layer In addition, regarding the thickness of the transparent resin layer C, when the thickness of the CFRP layer S is small, it is preferable to set the weight per unit area of the resin film used as a material to 5% or more (more preferably 5～100%, especially 10～50%). In addition, when the thickness of the CFRP layer S is large (when a thick plate is formed), the basis weight of the resin film may be made smaller than 5% relative to the basis weight of the entire UD sheet.

"Manufacturing method of CFRP sheet (i)" Next, the manufacturing method (i) of the CFRP sheet described above will be described. In this production method, first, the UD sheet is cut to produce a uniform rectangular UD sheet, and then a plurality of UD sheets arranged side by side in the two-dimensional direction and a thermoplastic resin film as a material of the transparent resin layer are rolled and formed. While temporarily following the two, an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated is produced. Then, the intermediate sheet produced by roll forming is further hot pressed to deform the UD sheet of the surface layer, and then cooled and pressed.

Furthermore, regarding the principle of deformation of the UD sheet of the above-mentioned surface layer, it is presumed that when transparent resin flows (deforms) into the fine irregularities on the surface of the CFRP layer, the carbon fibers of the UD sheet weakened by heating are seduced to move and occur. By. In addition, during the above hot pressing, the UD sheet of which the bonding strength of the carbon fibers weakens collapses, the carbon fibers move in the width direction, and the thickness of the UD sheet of the surface layer becomes smaller than the thickness of the UD sheet of the back layer or the intermediate layer. And the width dimension of the UD sheet of the surface layer becomes larger than the width dimension of the UD sheet of the back layer or the intermediate layer.

In addition, in this production method, the fluidity (deformability) of the transparent resin is improved by making the pressure applied to the intermediate sheet material greater than the pressure applied to the roll forming when temporarily bonding the UD sheet and the resin film , The shape of the UD sheet on the surface layer is greatly distorted. Furthermore, by increasing the pressure applied to the intermediate sheet material by hot pressing, more loosened portions can be formed in the UD sheet of the surface layer.

In addition, in this production method, as described above, a thermoplastic resin film is used as the material of the transparent resin layer, but instead of the resin film, a granular or short-fiber thermoplastic resin may be laminated, temporarily adhered to the UD sheet, and then hot pressed In order to form a transparent resin layer, the UD sheet of the surface layer can be deformed in the same way as described above. In addition, the weight per unit area of the resin film is preferably 5% or more (more preferably 5 to 100%, and particularly preferably 10 to 50%) relative to the weight per unit area of the entire UD sheet.

In addition, regarding the method of manufacturing the above-mentioned intermediate sheet material, it is not necessary to use a resin film, and for a large number of UD sheets arranged side by side in the direction of the two-dimensional element, by applying a molten resin as a material of a transparent resin layer and hot pressing , And the intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated is prepared. In addition, at that time, it is preferable to make the pressure applied to the hot pressing of the intermediate sheet material larger than that applied to the UD sheet coated with molten resin.

"Manufacturing method of CFRP sheet (ii)" Next, the manufacturing method (ii) of the above CFRP sheet will be described. In this manufacturing method, a continuous-fiber-shaped carbon fiber and a thermoplastic resin are roll-formed and then carbon fibers are bonded to each other to produce a UD sheet, and at the same time, the UD sheet is cut to produce a uniform rectangular UD sheet. Then, on the thermoplastic resin film as the material of the transparent resin layer, the UD sheets are arranged side by side in the direction of the two-dimensional element, and these are heated and compression-molded (press-formable, etc.) to deform the UD sheet of the surface layer to produce a sheet Ontology.

In addition, in this production method, the fluidity (deformability) of the transparent resin can be improved by making the pressure applied to the heating and compression molding of the resin film and the UD sheet greater than the pressure applied to the roll forming at the time of UD sheet production. , Distorted the shape of the UD sheet of the surface layer. In addition, by increasing the pressure applied to the heat and compression molding of the resin film and the UD sheet, more loosened portions can be formed in the UD sheet of the surface layer.

In addition, in this manufacturing method, instead of the thermoplastic resin film, a granular or short-fiber thermoplastic resin may be laminated to form a transparent resin layer. At that time, the UD sheet of the surface layer may be deformed in the same manner as described above. In addition, the weight per unit area of the resin film is preferably set to a size of 5% or more (more preferably 5 to 100%, particularly preferably 10 to 50%) with respect to the weight per unit area of the entire UD sheet.

In addition, regarding the above-mentioned heat compression molding, it is not necessary to use a resin film, and it may be carried out on a plurality of UD sheets arranged side by side with a molten resin coated with a material as a transparent resin layer.

"Second Embodiment" [1] Basic composition of CFRP sheet First, in this embodiment, as shown in FIG. 4(a)(b)(c), in order to reduce the number of overlapping UD sheets P·Q, the CFRP layer S is formed thinly, and at the same time on the surface layer and the back surface of the CFRP layer S The UD sheet P·Q of the layer includes both a non-rectangular sheet deformed. Furthermore, in the present embodiment, the average area of each of the UD sheets P in the surface layer of the CFRP layer S is larger than the average area of the UD sheet Q in the back layer.

In addition, it is preferable that the CFRP layer S is set to have a thickness of 0.1 mm to 0.2 mm (the average number of overlapping UD sheets P and Q is 2 to 4 sheets) so that the transparent resin enters the back layer. In addition, in the UD sheet P of the surface layer of the CFRP layer S, the ratio of the UD sheet P deformed into a non-rectangular shape is preferably 30% or more (preferably 50% or more).

By constructing the sheet body as described above, a unique appearance can be imparted to the sheet body. In addition, the transparent resin layer C formed outside the surface layer of the CFRP layer S can also improve the smoothness of the surface of the sheet body, and can also give the CFRP layer S a protective effect or an optical visual effect. In addition, other configurations and manufacturing methods are the same as those in the first embodiment.

"Third Embodiment" "Structure of laminates using CFRP sheets" Next, a third embodiment of the present invention will be explained. In this embodiment, the CFRP sheet of the first embodiment is hot-pressed on the surface of the plastic material and integrated with the laminate to form a laminate (not shown) with excellent surface design. In addition, as the object of stacking CFRP sheets, not only plastic materials but also different materials such as the same kind of CFRP materials or metals can be used. [Example]

[Empirical test of effect (i)] Next, the empirical test (i) of the effect of the present invention will be described. In this test, a plurality of samples of non-rectangular CFRP sheets with different ratios and widths of UD sheets with or without a transparent resin layer and a surface layer were prepared, and these samples were evaluated (Example 1 and Comparative Example 1 below ~ 2) Appearance.

"Example 1" In this embodiment, in the CFRP sheet made of the structure of the first embodiment, the matrix resin in the CFRP layer and the thermoplastic resin in the transparent resin layer are made of polyamide resin (nylon 6), respectively. Method (i) is used to make samples. Furthermore, in this embodiment, the pressing force for the roll forming at the time of temporary bonding (the pressing force when manufacturing the intermediate sheet) is 0.2 to 0.4 MPa, and the pressing force for the hot pressing of the intermediate sheet (from the middle The pressure applied when manufacturing the sheet body of the sheet material) was set to 3 MPa.

Then, a part of the surface layer of the CFRP layer (10cm×10cm=100cm ² ) was visually confirmed. As a result, the ratio of the non-rectangular UD sheet in the surface layer was 100%, and the width of the UD sheet was enlarged from the state before molding The proportion of those who are more than 1.5 times larger is also 100%. As a result, an appearance as shown in FIG. 5 is obtained, and a sample with a high appearance design having a unique appearance can be produced.

"Comparative Example 1" In this example, in the CFRP sheet composed of the configuration of the first embodiment, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer. ), in the same manner as in Example 1, a sample was prepared by the method of manufacturing method (i). Then, visually confirm a part of the back layer of the CFRP layer (10cm×10cm=100cm ² ). As a result, the proportion of the non-rectangular UD sheet in the back layer stays at 24%, and the width of the UD sheet is enlarged to more than 1.5 times the size The proportion of those staying at 18%. As a result, the appearance is as shown in FIG. 6(a), and the design effect of the sample cannot be sufficiently improved.

"Comparative Example 2" In this example, in a CFRP sheet made of only a CFRP layer that does not have a transparent resin layer, a polyamide resin (nylon 6) was used as the matrix resin in the CFRP layer, and the UD sheet Samples are prepared by hot pressing. Then, a part of the surface layer of the CFRP layer (10cm×10cm=100cm ² ) was visually confirmed. As a result, the ratio of the non-rectangular UD sheet in the surface layer was 0%, and the width of the UD sheet was enlarged from the state before molding to 1.5 The proportion of those who are more than doubled is also 0%. As a result, the appearance is as shown in FIG. 6(b), and the design effect of the sample cannot be sufficiently improved.

<Test Results> Summarizing the test results of the above Example 1 and Comparative Examples 1 to 2, the sample system of Example 1 can sufficiently improve the design of the style, and the sample systems of Comparative Examples 1 to 2 cannot sufficiently improve the style. Design. The following shows a table summarizing the conditions and test results of each sample.

[Empirical test of effect (ii)] Next, an empirical test (ii) of the effect of the present invention will be explained. In this test, samples of a plurality of transparent resin layer materials and CFRP sheets with different widths and Vf values of UD sheets used as the materials were prepared, and these samples were evaluated (Example 1 and Comparative Examples 1 to 4 below) 2) Appearance.

"Example 1" In this example, in the CFRP sheet formed by the configuration of the second embodiment, the matrix resin in the CFRP layer and the thermoplastic resin in the transparent resin layer were made of polyamide resin (nylon 6), respectively. Method (i) makes samples. In this embodiment, as the material, a UD sheet having a size of 5 mm in width×20 mm in length×0.043 mm in thickness and Vf53% is used.

Moreover, in this embodiment, the UD sheet and the thermoplastic resin film as the material of the transparent resin layer side by side in the direction of the two-dimensional element are formed by roll forming under the conditions of a roll temperature of 270°C and a roll pressure of 0.5 MPa. An intermediate sheet with a weight per unit area of 150 g/m ² , a thickness of 0.15 mm, and Vf of 43.3%. Then, the intermediate sheet is hot-pressed at a mold temperature of 270°C, an applied pressure of 3 MPa, and a press time of 0.5 min, and then cooled at a mold temperature of 30° C., an applied pressure of 5 MPa, and a press time of 3 min. Press to produce a sheet body with a size of 381 mm in width × 277 mm in length × 0.12 mm in thickness and Vf 43.3%. As a result, it is possible to produce samples with a unique appearance and high design.

"Example 2" In this embodiment, in the CFRP sheet formed by the configuration of the second embodiment, the matrix resin for the CFRP layer uses polyphenylene sulfide (PPS) resin, and the thermoplastic resin for the transparent resin layer uses polyamide resin. The sample was prepared by the manufacturing method (i). In this embodiment, as the material, a UD sheet having a size of 5 mm in width×20 mm in length×0.048 mm in thickness and Vf47% is used.

Moreover, in this embodiment, the UD sheet and the thermoplastic resin film as the material of the transparent resin layer side by side in the direction of the two-dimensional element are formed by roll forming under the conditions of a roll temperature of 270°C and a roll pressure of 0.5 MPa. An intermediate sheet with a weight per unit area of 150 g/m ² , a thickness of 0.15 mm, and Vf 35%. Then, this intermediate sheet is hot-pressed under the conditions of a mold temperature of 320°C, an applied pressure of 3 MPa, and a press time of 0.5 min, and then cooled at a mold temperature of 30° C., an applied pressure of 5 MPa, and a press time of 3 min. Pressed to produce a sheet body with dimensions of 381 mm in width × 277 mm in length × 0.12 mm in thickness and 35% Vf. As a result, it is possible to produce samples with a unique appearance and high design.

"Example 3" In this embodiment, in the CFRP sheet formed by the configuration of the second embodiment, polycarbonate (PC) resin is used for the matrix resin of the CFRP layer, and polyamide resin is used for the thermoplastic resin of the transparent resin layer. The sample was prepared by the manufacturing method (i). In this embodiment, as the material, a UD sheet having a size of 5 mm in width×20 mm in length×0.048 mm in thickness and Vf47% is used.

Moreover, in this embodiment, the UD sheet and the thermoplastic resin film as the material of the transparent resin layer side by side in the direction of the two-dimensional element are formed by roll forming under the conditions of a roll temperature of 270°C and a roll pressure of 0.5 MPa. An intermediate sheet with a weight per unit area of 150 g/m ² , a thickness of 0.15 mm, and a Vf35%. Then, the intermediate sheet is hot-pressed under the conditions of a mold temperature of 300° C., an applied pressure of 3 MPa, and a press time of 0.5 min. The mold temperature was 30°C, the pressure was 5 MPa, and the pressure time was 3 minutes. The cooling and pressing were performed to produce a sheet body with a size of 381 mm in width × 277 mm in length × 0.12 mm in thickness and Vf 35%. As a result, it is possible to produce samples with a unique appearance and high design.

<Test Results> Summarizing the test results of the above Examples 1 to 3, any of the samples of Examples 1 to 3 can sufficiently improve the design of the design. In addition, the following shows a table summarizing the conditions of each sample.

S‧‧‧CFRP layer M‧‧‧transparent resin layer P‧‧‧ UD sheet of surface layer Q‧‧‧ UD sheet on the back or middle layer

FIG. 1 is a schematic cross-sectional view showing a laminated structure of a CFRP sheet according to the first embodiment of the present invention. 2 is a schematic cross-sectional view and a schematic plan view showing the structure of the CFRP layer according to the first embodiment of the present invention. FIG. 3 is a schematic view showing the UD sheet of the surface layer and the UD sheet of the back layer or intermediate layer of the first embodiment of the present invention. 4 is a schematic cross-sectional view and a schematic plan view showing the structure of a CFRP layer according to a second embodiment of the present invention. Fig. 5 is a photograph showing the appearance of an example in an empirical test of the effect of the present invention. 6 is a photograph showing the appearance of a comparative example in an empirical test of the effect of the present invention.

S‧‧‧CFRP layer

C‧‧‧Transparent resin layer

Claims (11)

A CFRP sheet, which is a CFRP sheet formed by forming a transparent resin layer (C) on the outside of the surface layer of the CFRP layer (S), characterized by: The CFRP layer (S) is a state in which continuous fibrous carbon fibers (F) (F)... are aligned in the longitudinal direction, and the matrix resin (M) is then integrated into a plurality of UD sheets to make each The state in which the fiber directions of the sheets are randomly aligned, and the way in which the sheets are superimposed on each other, are formed by the matrix resin (M) in the state of being side by side in the direction of the secondary element, on the other hand, The UD sheet (Q) (Q) of the back layer or the intermediate layer of the CFRP layer (S) is rectangular, and the UD sheet (P) (P) of the surface layer... The UD sheet (Q) of the layer is smaller, and at least a part of it is deformed into a non-rectangular sheet. A CFRP sheet, which is a CFRP sheet formed by forming a transparent resin layer (C) on the outside of the surface layer of the CFRP layer (S), characterized by: The CFRP layer (S) is a state in which continuous fibrous carbon fibers (F) (F)... are aligned in the longitudinal direction, and the matrix resin (M) is then integrated into a plurality of UD sheets to make each The state in which the fiber directions of the sheets are randomly aligned, and the way in which the sheets are superimposed on each other, are formed by the matrix resin (M) in the state of being side by side in the direction of the secondary element, on the other hand, The UD sheet (P) (Q) of the surface layer and the back layer of the CFRP layer (S) is composed of a sheet including a non-rectangular shape deformed. As for the CFRP sheet of claim 1 or 2, the proportion of the surface layer of the CFRP layer (S) deformed into a non-rectangular UD sheet (P) is 30% or more. Such as the CFRP sheet of claim 1 or 2, wherein the average area of each of the UD sheets (P) in the surface layer of the CFRP layer (S) is larger than the average area of the UD sheets (Q) of the back layer or the middle layer . As in the CFRP sheet of claim 1 or 2, the ratio of the loosened portion (L) of the carbon fibers in the UD sheet (P) of the surface layer of the CFRP layer (S) that are partially separated from each other is smaller than that of the back layer or the middle layer The UD sheet (Q) is larger. The CFRP sheet according to claim 1 or 2, wherein the matrix resin in the CFRP layer (S) uses a thermoplastic resin having adhesion to the thermoplastic resin of the transparent resin layer (C). A laminated body using CFRP, which is characterized by integrating the CFRP sheet as claimed in claim 1 or 2 on the surface of the same material or different materials. A method of manufacturing a CFRP sheet, characterized by temporarily forming a plurality of UD sheets side by side in a two-dimensional direction and a resin film as a material of a transparent resin layer by roll forming, or by rolling in a two-dimensional direction Most of the UD sheets arranged side by side are coated with a molten resin as a material of the transparent resin layer, and hot-pressed to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated, and by further hot-pressing the intermediate sheet material The UD sheet of the surface layer is deformed. The manufacturing method of CFRP sheet according to claim 8, wherein the pressing force for the hot pressing of the intermediate sheet material is higher than the pressing force for the roll forming when the UD sheet and the resin film are temporarily adhered or for the UD sheet coated with molten resin The pressure of hot pressing is greater. A method for manufacturing CFRP sheets, characterized by: rolling and molding continuous fibrous carbon fibers and thermoplastic resins, followed by carbon fibers to produce UD sheets, and cutting the UD sheets into rectangular shapes at the same time. The UD sheet is arranged on the resin film which is the material of the transparent resin layer in the direction of the secondary element, or by applying a molten resin which is the material of the transparent resin layer on a plurality of UD sheets side by side in the direction of the second element, and heating and compressing Forming, and deforming the UD sheet of the surface layer. The method for manufacturing a CFRP sheet according to any one of claims 8 to 10, wherein the basis weight of the resin film is 5% or more relative to the basis weight of the entire UD sheet.

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