WO2013187220A1 - Matériau composite à fibre de carbone, article moulé formé à l'aide de celui-ci et procédés de production respectifs - Google Patents

Matériau composite à fibre de carbone, article moulé formé à l'aide de celui-ci et procédés de production respectifs Download PDF

Info

Publication number
WO2013187220A1
WO2013187220A1 PCT/JP2013/064655 JP2013064655W WO2013187220A1 WO 2013187220 A1 WO2013187220 A1 WO 2013187220A1 JP 2013064655 W JP2013064655 W JP 2013064655W WO 2013187220 A1 WO2013187220 A1 WO 2013187220A1
Authority
WO
WIPO (PCT)
Prior art keywords
carbon fiber
thermoplastic resin
composite material
fiber composite
molded
Prior art date
Application number
PCT/JP2013/064655
Other languages
English (en)
Japanese (ja)
Inventor
冨岡和彦
中野和良
Original Assignee
東洋プラスチック精工株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 東洋プラスチック精工株式会社 filed Critical 東洋プラスチック精工株式会社
Priority to JP2013534875A priority Critical patent/JP5608818B2/ja
Publication of WO2013187220A1 publication Critical patent/WO2013187220A1/fr

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/02—Making granules by dividing preformed material
    • B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/12—Making granules characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/12—Making granules characterised by structure or composition
    • B29B9/14—Making granules characterised by structure or composition fibre-reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/919—Thermal treatment of the stream of extruded material, e.g. cooling using a bath, e.g. extruding into an open bath to coagulate or cool the material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
    • C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0027—Cutting off
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/04—Particle-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B29C48/2886—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/307—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets specially adapted for bringing together components, e.g. melts within the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/355—Conveyors for extruded articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
    • B29C48/387—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a gear pump
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/76—Venting, drying means; Degassing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings

Definitions

  • the present invention relates to a carbon fiber composite material that is improved in mechanical properties and easy to post-process and is suitable for extrusion molding, a molded product using the carbon fiber composite material, and the carbon fiber composite material and the molded product. It relates to a manufacturing method.
  • a carbon fiber composite material has been obtained by preparing a prepreg in which carbon fiber is impregnated with a liquid thermosetting resin and subjecting the prepreg to autoclaving at high temperature and pressure.
  • expensive equipment such as low-temperature equipment for storing prepregs at low temperatures and high-temperature equipment for autoclaves is required, and it has been a heavy burden to have these equipments.
  • Patent Document 1 discloses a molding material in which a thermoplastic resin is coated around a continuous carbon fiber bundle. Is cut to 50 mm or less. In such a configuration, it is preferable to use a low-viscosity thermoplastic resin in order to improve the adhesion between the carbon fiber and the resin.
  • the low-viscosity resin is suitable for injection molding in which molding is performed by filling the resin in the mold, but in extrusion molding in which the molten resin is poured from the extruder into a die, the molded product
  • the shape is not stable, and the machinability and mechanical properties tend to be insufficient, and a method of using a high-viscosity thermoplastic resin together has been sought.
  • Patent Document 2 discloses a method for producing a pellet in which a bundle of carbon fibers is coated with a low viscosity thermoplastic resin and then coated with a high viscosity thermoplastic resin. It is disclosed. However, when the pellets obtained by this method are used for extrusion molding, the low-viscosity thermoplastic resin and the high-viscosity thermoplastic resin are completely separated, and the dispersion of carbon fibers in the resin becomes insufficient. In many cases, cracks and voids are generated at the time of molding or after molding, and it was difficult to use them as products.
  • Patent Document 3 discloses a long fiber reinforced synthetic resin strand formed by impregnating synthetic resin into a long fiber that has been aligned, or a long fiber reinforced synthetic resin pellet cut to an arbitrary length, and having a fiber content of What is comprised by the high layer and the layer with a low fiber content rate is disclosed.
  • the impact strength of the molded product is good because the strand or pellet maintains a state in which the long fibers are bundled and aligned, the fiber
  • the resin for impregnating the bundle has a low viscosity and the impregnation speed is fast, and other than the resin for impregnating the fiber bundle, a composite strand that uses another resin to compensate for problems such as insufficient molecular weight of the resin or It is mentioned that since it is a pellet, a molded product having high strength and high elasticity can be obtained.
  • the present invention has been made in view of the problems of the prior art, and the object thereof is a carbon fiber composite material comprising a thermoplastic resin and carbon fibers, excellent in mechanical properties and processability, and suitable for extrusion molding.
  • An object of the present invention is to provide a molded article using the fiber composite material, and a method for producing the carbon fiber composite material and the molded article.
  • a carbon fiber composite material according to the present invention a molded product using the carbon fiber composite material, and a manufacturing method thereof have the following configurations.
  • a pellet having a core-sheath structure in which the core component is made of carbon fiber and the sheath component is made of the first thermoplastic resin and the second thermoplastic resin are melted, and the molten pellet and the second thermoplastic resin are melted.
  • the second thermoplastic resin has a higher viscosity than the first thermoplastic resin at the predetermined temperature.
  • Method. The method for producing a carbon fiber composite material according to (1), wherein the viscosity of the second thermoplastic resin is 10 to 750 times the viscosity of the first thermoplastic resin at a predetermined temperature.
  • the viscosity of the first thermoplastic resin at a predetermined temperature is 50 to 500 poise, and the viscosity of the second thermoplastic resin at a predetermined temperature is 1,000 to 10,000 poise (1) or (2) Of carbon fiber composite material.
  • the intermediate molded body is further molded by a press molding method, a vacuum molding method, a blow molding method, or a bending process.
  • Production method (11) The method for producing a molded article according to (10), wherein the intermediate molded body is hot-pressed under conditions of a pressure of 0.2 to 100 MPa and a temperature of 100 to 370 ° C.
  • the carbon fiber composite material of the present invention By using the carbon fiber composite material of the present invention, cracks and voids generated in the product can be suppressed in extrusion molding. As a result, post-processing such as pressing or bending by cutting or heat treatment can be easily performed. In addition, since the resin is thermoplastic, it is possible to provide a molded product that can be easily recycled.
  • FIG. 1 It is a schematic perspective view which shows the pellet which consists of a carbon fiber composite material which concerns on one embodiment of this invention. It is a partial expanded sectional view for demonstrating the structure of the pellet shown in FIG. 1, (a) is a schematic cross section which shows an example of the structure of a carbon fiber composite material, (b) is a side cross section of a carbon fiber composite material. It is a cross-sectional observation figure which shows an example of the result observed with the electron microscope. It is a schematic perspective view which shows an example of the pellet which has the conventional 3 layer structure. It is a schematic perspective view which shows an example of the pellet which has the conventional 2 layer structure. It is a manufacturing process figure which shows an example of the manufacturing method of the pellet of FIG.
  • FIG. 15 is a schematic cross-sectional view illustrating a cross-sectional shape of a deformed product manufactured by the manufacturing method of FIG. 14, where (a) illustrates a cross-sectional shape of an I-shaped product, (b) illustrates a cross-sectional shape of an H-shaped product, ( c) shows the cross-sectional shape of the T-shaped variant. It is a manufacturing process figure which shows an example of the manufacturing method of the molded article by the solidification extrusion method.
  • FIG. 16 It is a schematic sectional drawing which illustrates the cross-sectional shape of the molded article manufactured by the manufacturing method of FIG. 16, (a) has shown the cross-sectional shape of the extrusion block, (b) has shown the cross-sectional shape of the round bar.
  • (d) is a step of opening the mold and taking out the molded body
  • (e) is a process of deburring the molded body to obtain a molded product.
  • Step (a) is the process of heating the sheet
  • Step (c) is a step of closing the mold and performing blow molding,
  • (d) is a step of opening the mold and taking out the molded product holder, and
  • (e) is a step of removing the holder and deburring the molded body.
  • the step of obtaining a molded product by performing (f) shows a cross-sectional view of the obtained molded product.
  • Step (a) is the process which puts the carbon fiber composite material sheet
  • Step (c) shows a step of opening the mold and taking out the molded body, and
  • a pellet having a core-sheath structure in which a core component is made of carbon fiber and a sheath component is made of a first thermoplastic resin and a second thermoplastic resin are melted and melted.
  • the second thermoplastic resin has a higher viscosity than the first thermoplastic resin at the predetermined temperature. It consists of a characteristic method.
  • the present invention also provides a carbon fiber composite material produced by the above production method. That is, the carbon fiber composite material in the present invention is composed of the first thermoplastic resin, the second thermoplastic resin, and the carbon fiber, and the first thermoplastic resin is contained in the sea phase composed of the second thermoplastic resin. It consists of what has the structure where the island phase comprised from resin has disperse
  • a carbon fiber composite material is sometimes referred to as a hybrid carbon fiber composite resin or a hybrid alloy carbon fiber composite resin.
  • an island phase having an average diameter (described later) of 1 ⁇ m or less has excellent characteristics similar to those of Nanoalloy (registered trademark), and is sometimes called a hybrid nanoalloy carbon fiber composite resin.
  • a carbon fiber composite material used as a molding material the most important point at the time of molding is high affinity between carbon fiber and resin, that is, high adhesion. Moreover, generally in a thermoplastic resin, adhesiveness with carbon fiber becomes high, so that a viscosity is low. Therefore, for example, it is conceivable to produce a carbon fiber composite material using pellets made of carbon fiber and a low-viscosity resin. However, if only a low-viscosity resin is used as the resin of the carbon fiber composite material, the resin will follow the orientation of the carbon fiber during molding, so that the carbon fiber repels the resin, such as springback, cracks, voids, etc. There is a risk of problems, and it is difficult to obtain the desired molded product.
  • the carbon fiber is encapsulated with the first thermoplastic resin having a relatively low viscosity so that the affinity between the carbon fiber and the resin is increased.
  • the first thermoplastic resin By covering the first thermoplastic resin with the second thermoplastic resin having a relatively high viscosity while securing the properties, problems such as springback, cracks and voids can be suppressed, and the target molded product can be obtained. Be able to get.
  • the carbon fiber, the first thermoplastic resin, and the second thermoplastic resin are all uniformly dispersed, a highly rigid molded product can be obtained.
  • the refractive index of the first thermoplastic resin is preferably different from the refractive index of the second thermoplastic resin.
  • the ratio of the carbon fibers present in the island phase is more preferably 70% by weight or more, and further preferably 90% by weight or more.
  • the fiber diameter of the carbon fiber in the present invention is preferably 0.5 to 20 ⁇ m, more preferably 5 to 15 ⁇ m. If the fiber diameter is too large, the repulsion will be strong during the heat bending process of the molded product, which may cause twisting and unevenness. Further, if the fiber diameter is thin, the mechanical strength of the molded product may be reduced.
  • the proportion of carbon fiber is preferably 5 to 60% by weight, more preferably 15 to 50% by weight, and further preferably 20 to 40% by weight. .
  • the above-mentioned predetermined temperature is preferably higher than the melting point of the second thermoplastic resin (or the glass transition point when the second thermoplastic resin is amorphous). Further, the difference between the predetermined temperature and the melting point of the second thermoplastic resin is preferably 30 to 90 ° C., more preferably 40 to 90 ° C.
  • the melting point of the first thermoplastic resin is preferably 100 to 370 ° C.
  • the melting point of the second thermoplastic resin is preferably 100 to 370 ° C.
  • the viscosity of the second thermoplastic resin is preferably 10 to 750 times, more preferably 20 to 500 times, and more preferably 50 to 200 times the viscosity of the first thermoplastic resin at the predetermined temperature. More preferably.
  • the viscosity of the first thermoplastic resin is 50 to 500 poise and the viscosity of the second thermoplastic resin is 1,000 to 10,000 poise. Furthermore, it is more preferable that the viscosity of the first thermoplastic resin is 100 to 300 poise and the viscosity of the second thermoplastic resin is 1,500 poise to 5000 poise at the predetermined temperature.
  • first thermoplastic resin and the second thermoplastic resin may have the same or different resin components.
  • a resin having a relatively low viscosity is designated as a first thermoplastic resin
  • a resin having a relatively high viscosity is designated as a second heat. It can also be used as a plastic resin.
  • the thermoplastic resin used to produce the carbon fiber composite material may be a polyolefin (eg, polyethylene, polypropylene (PP), polybutylene, polystyrene) or a polyamide (eg, nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, May be polyimide, polyamideimide, or polycarbonate, or polyester (eg, polyethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate), or polyphenylene sulfide (PPS), polysulfoxide, or polytetrafluoroethylene.
  • a polyolefin eg, polyethylene, polypropylene (PP), polybutylene, polystyrene
  • a polyamide eg, nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, May be polyimide, polyamideimide, or polycarbonate, or polyester (eg, polyethylene terephthalate, polybutylene terephthalate, polypropylene ter
  • ABS Acrylonitrile butadiene styrene copolymer
  • guide_body Acrylonitrile butadiene styrene copolymer
  • polyacetal polyether
  • polyether ether ketone It may be re-oxymethylene.
  • guide_body the copolymer of the said thermoplastic resin, and those mixtures may be sufficient.
  • thermoplastic resin polyamide is preferable, nylon 6, nylon 66, derivatives or copolymers thereof, or a mixture containing any of the above, more preferably nylon 6, nylon 66.
  • the thermoplastic resin is also preferably a polyolefin, more preferably polyethylene, polypropylene, derivatives or copolymers thereof, or a mixture containing any of the above, and further preferably polyethylene or polypropylene.
  • an acrylonitrile butadiene styrene copolymer, a derivative or copolymer thereof, or a mixture containing any of the above is also preferable.
  • polyphenylene sulfide, a derivative or copolymer thereof, or a mixture containing any of the above is also preferable.
  • the average diameter of the island phase is preferably 10 nm to 500 ⁇ m.
  • the average diameter of an island phase refers to the average value of the diameter when each island phase is converted into a perfect circle of the same area in the cross section of the carbon fiber composite material.
  • the average diameter is preferably 1 ⁇ m to 500 ⁇ m, and more preferably 1 ⁇ m to 100 ⁇ m.
  • the average diameter is preferably 10 nm to 1 ⁇ m, more preferably 50 nm to 1 ⁇ m, and more preferably 150 nm to 1 ⁇ m. Further preferred.
  • a vacuum vent is preferably provided in the latter half of the cylinder of the extruder, and more preferably a gear pump is provided at the tip of the extruder.
  • carbon fibers can be further added to the molten pellets and the second thermoplastic resin.
  • the content rate of the carbon fiber in a carbon fiber composite material can be raised, and intensity
  • the method for adding the carbon fiber include a method for directly supplying the carbon fiber filament drawn from the carbon fiber roving to the extruder, and a method for supplying the carbon fiber cut to an appropriate length to the extruder. However, it is not limited to these.
  • the carbon fiber composite material is suitable for molding applications. That is, a molded product excellent in mechanical strength and workability can be obtained by melting the carbon fiber composite material and then molding the carbon fiber composite material.
  • the above carbon fiber composite material made of carbon fiber and thermoplastic resin is suitable for extrusion molding in which it was difficult to suppress problems such as springback in the prior art, and both the melt extrusion method and the solidification extrusion method are suitable. Available.
  • the said carbon fiber composite material can be used suitably also for the conventional injection molding.
  • the molding method is not particularly limited.
  • a mandrel manufacturing method described in JP-A-4-152122, a resin mandrel extrusion molding apparatus, and a melt extrusion synthesis described in JP-A-2001-315193 are disclosed.
  • a molded product made of the carbon fiber composite material can be obtained.
  • the shape of the molded product can be adjusted to a desired shape by performing heating, cooling, decompression (vacuum decompression), heat insulation and the like around the die.
  • the molded product made of the carbon fiber composite material obtained by the above molding method can be further subjected to secondary processing to be reshaped into a desired shape.
  • Secondary processing methods include, for example, different material lamination, same material lamination, in-mold heating, out-of-mold heating, in-mold cooling, out-of-mold cooling, in-mold pressurization, out-of-mold pressurization, in-mold decompression (vacuum decompression), Examples include out-of-mold depressurization, in-mold heat bending, out-of-mold heat bending, stretching, heat insulation, and the like, and these methods may be combined.
  • molding it can also shape
  • the carbon fiber composite material may contain materials other than the above-described pellets, resins, and carbon fibers. For example, it may contain 1 to 10% by weight of thermosetting resin for convergence of carbon fiber bundles or surface treatment. Further, a silane coupling agent such as amino silane, epoxy silane, amide silane, azido silane, and acrylic silane, a titanate coupling agent, or a mixture thereof may be included.
  • a silane coupling agent such as amino silane, epoxy silane, amide silane, azido silane, and acrylic silane, a titanate coupling agent, or a mixture thereof may be included.
  • a well-known method can be used as a manufacturing method of the pellet which has a core sheath structure.
  • an impregnation die having a resin impregnation roll is installed, and the first thermoplastic resin melted by the extruder is stored in the resin tank of the impregnation die.
  • the opened roving-like carbon fiber is introduced into the resin tank of the impregnation die, and the carbon fiber roving is sandwiched between the impregnation rollers while the surface of the carbon fiber roving is covered with the first thermoplastic resin.
  • the resin is impregnated into the carbon fiber roving.
  • the carbon fiber roving is transported by pulling the carbon fiber roving by a feed roller located downstream of the resin tank.
  • the carbon fiber roving conveyed downstream is fed into a cutting device having a cutter after the resin amount is adjusted by the die and the cross-sectional shape is adjusted. Then, by cutting the carbon fiber roving covered with the first thermoplastic resin with a cutter of a cutting device, a pellet having a core-sheath structure in which a core made of carbon fiber is covered with the first thermoplastic resin. Obtainable.
  • the pellet which consists of a 2nd thermoplastic resin is added to the pellet which has the core-sheath structure obtained by this method, These pellets are knead
  • the pellets made of the carbon fiber composite material can be manufactured by feeding into a cutting device having a cutter and cutting.
  • An additive may be added to the thermoplastic resin as long as its properties are not significantly impaired.
  • hindered phenols, phosphorus compounds, hindered amines, sulfur compounds, copper compounds, alkali metal halides or mixtures thereof are heat stabilizers, antioxidants, reinforcing materials, pigments, anti-coloring agents, weathering agents, You may add as additives, such as a flame retardant, a plasticizer, a crystal nucleating agent, and a mold release agent.
  • the molding process may be performed a plurality of times.
  • a carbon fiber composite material is once molded to form an intermediate molded body, and then the obtained intermediate molded body is further molded by a press molding method, a vacuum molding method, or a blow molding method.
  • the method of manufacturing can be adopted.
  • the method for heating the mold and the carbon fiber composite material is not particularly limited, and known heating means such as an electric heater, a gas oven, a dielectric coil, and high-pressure steam can be appropriately used.
  • ⁇ Burr formed around the molded product may be cut out at the same time when the mold is fitted, or may be extracted by Thomson punching in a separate process. Moreover, by completely filling the mold with a carbon fiber composite material sheet having a size smaller than that of the mold, the occurrence of burrs can be suppressed.
  • the carbon fiber composite material can be laminated and used, or can be used in combination with another material different from the carbon fiber composite material.
  • molding may be performed using a laminate formed by laminating a plurality of carbon fiber composite materials, or a laminate obtained by laminating a single or a plurality of carbon fiber composite materials with a single or a plurality of other materials. May be formed.
  • Other materials that can be laminated include, for example, metal, glass, PTFE, polyester, fiber made of thermoplastic resin such as polyamide, base fabric, nonwoven fabric, or sheet made of thermosetting resin such as polyurethane, and thermosetting type. Examples include CFRP sheets and tapes, and two or more kinds of materials can be used in combination.
  • such other materials may be disposed in any layer in the laminate, and may be laminated on the upper end and / or the lower end of the laminate.
  • glossy metal powder, minerals, rocks, and sands may be mixed in advance with the carbon fiber composite material.
  • the carbon fiber composite material when the carbon fiber composite material is laminated and used, it is preferable that the carbon fiber composite material is laminated so that the orientation direction of the carbon fiber intersects by 90 ° in consideration of the orientation state of the carbon fiber.
  • the physical property of a molded object can be improved by adjusting the orientation direction of carbon fiber.
  • each layer of the laminate may be composed of a single substantially sheet-like carbon fiber composite material, or may be composed of a combination of a plurality of carbon fiber composite materials.
  • a plurality of strip-shaped carbon fiber composite materials can be arranged in the width direction to form one layer, or a plurality of strip-shaped carbon fiber composite materials can be combined in a lattice shape to form a layer.
  • the pressure is preferably 0.2 to 100 MPa, more preferably 1 to 50 MPa.
  • the temperature of the hot press is preferably 100 to 370 ° C. More specifically, the mold temperature is preferably in the range of ⁇ 10 to 90 ° C., more preferably in the range of 0 to 50 ° C., based on the melting point of the thermoplastic resin contained in the carbon fiber composite material. preferable.
  • the method of hot press molding is not particularly limited, but examples thereof include the following methods. First, one or a plurality of carbon fiber composite materials are heated and melted at the above temperature, and then put into a mold, and the mold is closed and sealed. And in the state where the temperature of a metal mold
  • one or a plurality of carbon fiber composite materials are put into a mold whose mold temperature is adjusted to be equal to or lower than the melting point of the carbon fiber composite material, and the mold is closed. Subsequently, the temperature of the mold is heated to the above temperature to bring the carbon fiber composite material into a molten state and pressurized at the above pressure. At this time, the mold is sealed. Thereafter, the mold is cooled by cooling or water cooling, and after the carbon fiber composite material in the mold is solidified, the mold is opened and the molded product is taken out.
  • one or a plurality of carbon fiber composite materials are heated at the above temperature to be in a semi-molten state, and this is put into a mold. At this time, it is preferable that only the surface of the carbon fiber composite material is in a semi-molten state.
  • the mold is then closed, but not completely sealed, leaving the mold open. And after pressurizing with the said pressure in the state whose temperature of a metal mold
  • the shape of the carbon fiber composite material is preferably a sheet.
  • the thickness of the sheet is preferably from 0.1 to 3 mm, more preferably from 0.5 to 2 mm, and even more preferably from 1.0 to 1.5 mm.
  • the mold when the mold is composed of a convex mold and a corresponding concave mold, the arrangement of the mold is not particularly limited.
  • the upper mold may be a convex mold and the lower mold may be a corresponding concave mold, or vice versa.
  • the pressure is preferably 1 ⁇ 10 ⁇ 5 to 0.05 MPa, more preferably 0.5 ⁇ 10 ⁇ 4 to 0.05 MPa, X10 ⁇ 4 to 1 ⁇ 10 ⁇ 3 MPa is more preferable.
  • the temperature during vacuum forming is preferably 100 to 370 ° C. More specifically, the temperature is preferably in the range of ⁇ 10 to 90 ° C., more preferably in the range of 0 to 50 ° C., based on the melting point of the thermoplastic resin contained in the carbon fiber composite material.
  • the vacuum forming method is not particularly limited, but examples thereof include the following methods. First, one or a plurality of carbon fiber composite materials are heated at the above temperature to be in a molten state, put into a mold, and the mold is closed. Then, in a state where the temperature of the mold is equal to or lower than the melting point of the carbon fiber composite material, after reducing the pressure at the above pressure, the mold is opened and the molded product is taken out. At this time, the pressure reduction may be performed on either the upper mold side or the lower mold side, or may be performed simultaneously on both the upper mold side and the lower mold side.
  • one or a plurality of carbon fiber composite materials are heated at the above temperature to be in a molten state, and this is put into a mold. Then, after raising the lower mold of the mold, suction is performed from the lower mold side at the above pressure, the mold is opened, and the molded product is taken out.
  • one or a plurality of carbon fiber composite materials are heated at the above temperature to be in a molten state, and this is put into a mold. Then, after raising the upper mold of the mold, suction is performed from the upper mold side at the above pressure, the mold is opened, and the molded product is taken out.
  • the shape of the carbon fiber composite material is preferably a sheet.
  • the pressure is preferably 0.1 to 10 MPa, and the pressure is preferably adjusted so that the carbon fiber composite material is not broken.
  • the blow pressure is preferably 0.2 to 10 MPa, more preferably 0.5 to 2 MPa.
  • the temperature at the time of blow molding is preferably 100 to 370 ° C. More specifically, the temperature is preferably in the range of ⁇ 10 to 90 ° C., more preferably in the range of 0 to 50 ° C., based on the melting point of the thermoplastic resin contained in the carbon fiber composite material.
  • the vacuum forming method is not particularly limited, but examples thereof include the following methods. First, one or a plurality of sheets made of a carbon fiber composite material are heated at the above temperature to be in a semi-molten state, and then blown to spread the sheet. At this time, it is preferable that only the surface of the sheet is in a semi-molten state. Subsequently, the semi-molten sheet is put into a mold, and the mold is closed and blown. At this time, the mold is in a sealed state. And after pressurizing with the said pressure in the state whose temperature of a metal mold
  • the bending method is not particularly limited, but examples thereof include the following methods. First, an I-shaped profile extrudate made of one or a plurality of carbon fiber composite materials is heated at 100 to 370 ° C. to be in a semi-molten state, fixed along the mold, and further heated to 100 to 370 ° C. in an oven. Heat with. And after cooling to room temperature, it removes from a type
  • Carbon fiber roving / filament A carbon fiber filament having a fiber diameter of 7 ⁇ m, a count of 200 tex, and a winding length of 30,000 m is prepared. Five filaments are combined, 2% by weight of a polyurethane sizing agent is applied, and a flat belt-like carbon fiber roving is prepared.
  • B1 First thermoplastic resin
  • B2 Nylon 66 (melting point: 255 ° C., viscosity at 305 ° C .: 250 poise)
  • B3 PP (melting point: 170 ° C., viscosity at 220 ° C .: 70 poise)
  • B4 ABS (glass transition point (softening point): 190 ° C., viscosity at 240 ° C .: 120 poise)
  • B5 PPS (melting point: 285 ° C., viscosity at 335 ° C .: 260 poise)
  • Second thermoplastic resin C1 Nylon 6 (melting point: 225 ° C., viscosity at 275 ° C .: 1,100 poise)
  • C2 nylon 66 (melting point: 255 ° C., viscosity at 305 ° C .: 5,
  • FIG. 7 shows a conventional method for producing a pellet having a core-sheath structure in which a core made of carbon fiber is covered with a thermoplastic resin.
  • the flat belt-like carbon fiber roving 46 is sent to the extruder 60 via the defibrating device 50, and the first thermoplastic resin B1 made of nylon 6 is put into the extruder 60, The melted first thermoplastic resin 61 (B1) is discharged to the carbon fiber roving through the die 51 at a temperature of 275 ° C., thereby covering the surface of the carbon fiber roving 46 with the resin B1.
  • the carbon fiber roving 46 drawn out from the die 51 is passed through a squeeze bar 52 and the degree of impregnation of the resin B1 into the carbon fiber is increased, the shape is adjusted by the convergence shaping portion 53 and the cooling portion 54 To be cooled. Then, the carbon fiber roving 46 whose surface is coated with the resin B1 is cut by the strand cutter 57 including the rotary blade 58 and the fixed blade 62 while being taken up by the top roller 55 and the bottom roller 56, thereby obtaining FIG.
  • pellet 6 pellet 59 in FIG. 7 having a core-sheath structure in which a core made of carbon fiber is covered with nylon 6 is obtained. In addition, the content rate of the carbon fiber in the obtained pellet 6 is 30%.
  • the core-sheath-type carbon fiber-containing resin pellet 6 is put into a pellet supply device 42 shown in FIG. 5, and the pellet is supplied into the extruder 22 through the supply port 30 from the pellet supply path P1. Moreover, the pellet which consists of 2nd thermoplastic resin C1 is thrown into the pellet supply apparatus 43, and the said pellet is supplied in the extruder 22 through the supply port 30 from the pellet supply path P2.
  • This second thermoplastic resin C1 is made of nylon 6 and has a higher viscosity than B1.
  • pellets are kneaded in an extruder 22 equipped with a motor 20 and a transmission 21 at a temperature of 275 ° C., deaerated with a vent 29, and poured into a die 26 while being metered with a gear pump 23. obtain.
  • the obtained gut 28 is cooled by the cooling unit 24 and then cut by the strand cutter 27 to obtain hybrid pellets 1 made of nylon 6 (pellets made of a carbon fiber composite material).
  • the carbon fiber content in the hybrid pellet 1 made of nylon 6 is 15% by weight.
  • the hybrid pellet was injection molded to produce a dumbbell piece having a measurement width of 10 ⁇ 0.5 mm and a measurement length of 80 ⁇ 2 mm.
  • the resulting dumbbell pieces had a bending strength of 250 MPa and a flexural modulus of 10.2 GPa.
  • FIG. 1 and 2 show the structure of a pellet 1 made of a carbon fiber composite material produced by the method described in Example 1.
  • FIG. FIG. 1 is a schematic perspective view showing a hybrid pellet 1 (a pellet made of a carbon fiber composite material) according to an embodiment of the present invention.
  • 2 is a partially enlarged cross-sectional view for explaining the structure of the hybrid pellet 1.
  • FIG. 2A is a schematic cross-sectional view showing the state of the cross-section 1a of the hybrid pellet 1, and FIG. It is sectional observation figure which shows the result of having observed the side cross section 1b of the hybrid pellet 1 manufactured by the method with the electron microscope.
  • FIG. 1 is a schematic perspective view showing a hybrid pellet 1 (a pellet made of a carbon fiber composite material) according to an embodiment of the present invention.
  • 2 is a partially enlarged cross-sectional view for explaining the structure of the hybrid pellet 1.
  • FIG. 2A is a schematic cross-sectional view showing the state of the cross-section 1a of the hybrid pellet 1, and FIG. It is
  • the hybrid pellet 1 has a structure in which island phases 3 composed of the first thermoplastic resin are dispersed in the sea phase 4 composed of the second thermoplastic resin.
  • the carbon fiber 2 and the island phase 3 are uniformly dispersed in the hybrid pellet 1. According to such a carbon fiber composite material, since defects (for example, springback and voids) due to the uneven distribution of carbon fibers and thermoplastic resins are prevented in advance, the surface can be used not only in injection molding but also in extrusion molding. A molded article having a good state and excellent rigidity can be obtained.
  • FIG. 4 shows the structure of the pellet 6 used in the method described in Example 1.
  • a pellet 6 made of a carbon fiber-containing resin has a core in which a core made of carbon fiber 2 is covered with a thermoplastic resin 3 (in Example 1, a first thermoplastic resin B1 made of nylon 6).
  • a first thermoplastic resin B1 made of nylon 6
  • the structure of the pellet which has a core-sheath structure is not limited only to the above, A various pellet can be utilized suitably.
  • a core made of carbon fiber 2 is covered with a thermoplastic resin 3, and a thermoplastic resin 4 having a higher viscosity than the thermoplastic resin 3 on the outside (for example, a second made of nylon 6).
  • the pellet 5 covered with the thermoplastic resin B2) as a raw material for the carbon fiber composite material.
  • Example 2 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B2 made of nylon 66 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 305 ° C., and the core made of carbon fiber is covered with the nylon 66. A core-sheath-type carbon fiber-containing resin pellet 6 having a core-sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 40 weight%. The core-sheath type carbon fiber-containing resin pellet 6 made of nylon 66 is put into the pellet supply device 42 shown in FIG. 5 and the pellet made of the second thermoplastic resin C2 is put into the pellet supply device 43.
  • This second thermoplastic resin C2 is made of nylon 66, and has a higher viscosity than B2. These pellets are kneaded at a temperature of 305 ° C., and hybrid pellets 1 made of nylon 66 are obtained by the manufacturing method shown in FIG. The carbon fiber content in the hybrid pellet 1 made of nylon 66 is 20% by weight.
  • Example 3 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B3 made of PP is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 220 ° C., and the core made of carbon fiber is covered with PP. A core-sheath type carbon fiber-containing resin pellet 6 having a sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 20 weight%. The core-sheath type carbon fiber-containing resin pellet 6 made of PP is put into the pellet feeder 42 shown in FIG. 5 and the pellet made of the second thermoplastic resin C3 is put into the pellet feeder 43.
  • the second thermoplastic resin C3 is made of PP and has a higher viscosity than B3. These pellets are kneaded at a temperature of 220 ° C., and hybrid pellets 1 made of PP are obtained by the manufacturing method shown in FIG. The content of carbon fiber in the hybrid pellet 1 made of PP is 15% by weight.
  • Example 4 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B4 made of ABS is discharged from the extruder 60 to a flat strip-like carbon fiber roving at a temperature of 240 ° C., and the core made of carbon fiber is covered with ABS. A core-sheath type carbon fiber-containing resin pellet 6 having a sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 25 weight%. The core-sheath type carbon fiber-containing resin pellet 6 made of ABS is put into the pellet supply device 42 shown in FIG. 5 and the pellet made of the second thermoplastic resin C4 is put into the pellet supply device 43.
  • This second thermoplastic resin C4 is made of ABS, and has a higher viscosity than B4. These are kneaded at a temperature of 240 ° C., and hybrid pellets 1 made of ABS are obtained by the manufacturing method shown in FIG. The content of carbon fiber in the hybrid pellet 1 made of ABS is 15% by weight.
  • Example 5 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B5 made of PPS is discharged from the extruder 60 to a flat strip-like carbon fiber roving at a temperature of 335 ° C., and the core made of carbon fiber is covered with PPS. A core-sheath type carbon fiber-containing resin pellet 6 having a sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 30 weight%. The core-sheath type carbon fiber-containing resin pellet 6 made of PPS is charged into the pellet supply device 42 shown in FIG. 5, and the pellet made of the second thermoplastic resin C5 is charged into the pellet supply device 43.
  • the second thermoplastic resin C5 is made of PPS and has a higher viscosity than B5. These pellets are kneaded at a temperature of 335 ° C., and hybrid pellets 1 made of PPS are obtained by the manufacturing method shown in FIG. The carbon fiber content of the hybrid pellet 1 made of PPS is 20% by weight.
  • Example 6 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B1 made of nylon 6 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 275 ° C., and the core made of carbon fiber is covered with the nylon 6. A core-sheath-type carbon fiber-containing resin pellet having a core-sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 30 weight%. The core-sheath type carbon fiber-containing resin pellet 6 made of nylon 6 is put into a pellet supply device 42 shown in FIG. 5, and the pellet is supplied to the extruder 22 through the supply port 30 from the pellet supply path P1.
  • pellets made of the second thermoplastic resin C1 are put into the pellet supply device 43, and the pellets are supplied to the extruder 22 through the side feeder 25 from the pellet supply route P3 instead of the pellet supply route P2. These pellets are kneaded at a temperature of 270 ° C., and hybrid pellets 1 made of nylon 6 are obtained by the manufacturing method shown in FIG. The carbon fiber content in the hybrid pellet 1 made of nylon 6 is 20% by weight.
  • Example 7 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B1 made of nylon 6 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 275 ° C., and the core made of carbon fiber is covered with the nylon 6. A core-sheath-type carbon fiber-containing resin pellet 6 having a core-sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 30 weight%. The core-sheath type carbon fiber resin pellet 6 of nylon 6 is put into a pellet supply device 42 shown in FIG. 5, and the pellet is supplied into the extruder 22 through the supply port 30 from the pellet supply path P1.
  • pellets made of the second thermoplastic resin C1 are put into the pellet supply device 43, and the pellets are supplied into the extruder 22 through the side feeder 25 from the pellet supply route P3 instead of the pellet supply route P2. And these pellets are knead
  • the carbon fiber content in the hybrid pellet 1 made of nylon 6 is 20% by weight.
  • Example 8 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B1 made of nylon 6 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 275 ° C., and the core made of carbon fiber is covered with the nylon 6. A core-sheath-type carbon fiber-containing resin pellet 6 having a core-sheath structure is obtained. The content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 30 weight%. The core-sheath type carbon fiber resin pellet 6 made of nylon 6 is put into a pellet supply device 42 shown in FIG. 5, and the pellet is supplied into the extruder 22 through the supply port 30 from the pellet supply path P1.
  • pellets made of the second thermoplastic resin C2 are charged into the pellet supply device 43, and the pellets are supplied into the extruder 22 through the side feeder 25 from the pellet supply route P3 instead of the pellet supply route P2. These pellets are kneaded at a temperature of 305 ° C., and hybrid pellets 1 made of nylon 6 and nylon 66 are obtained by the manufacturing method shown in FIG. The carbon fiber content in the hybrid pellet 1 is 15% by weight.
  • Example 9 In the manufacturing method shown in FIG. 7, the first thermoplastic resin B1 made of nylon 6 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 275 ° C., and the core made of carbon fiber is covered with the nylon 6. A core-sheath-type carbon fiber-containing resin pellet 6 having a core-sheath structure is obtained. The content rate of the carbon fiber in the core-sheath type carbon fiber-containing resin pellet 6 is 35% by weight. The core-sheath type carbon fiber resin pellet 6 made of nylon 6 is put into a pellet supply device 42 shown in FIG. 6, and the pellet is supplied into the extruder 22 through the supply port 30 from the pellet supply path P1.
  • the pellet which consists of a 2nd thermoplastic resin is thrown into the pellet supply apparatus 43, and the said pellet is supplied in the extruder 22 through the supply port 30 from the pellet supply path P2. Further, as shown in FIG. 6, a flat belt-like carbon fiber roving is supplied into the extruder 22 through the opening of the side feeder 25. These pellets and carbon fiber roving are kneaded at a temperature of 275 ° C., and hybrid pellets 1 made of nylon 6 are obtained by the manufacturing method shown in FIG. The content of carbon fiber in the hybrid pellet 1 made of nylon 6 is 47% by weight.
  • Example 10 Using the hybrid pellet 1 described in Example 1 above, extrusion molding was performed at a discharge rate of 200 g / min using the melt-extruded sheet manufacturing apparatus 111 shown in FIG. 9 to produce a sheet having a width of 300 mm and a thickness of 0.3 mm. . More specifically, in the melt extruded sheet manufacturing apparatus 111 shown in FIG. 9, the molten resin material 114 extruded from the die 112 into a sheet shape passes through between the heater rolls 116, 118, 120, and is then stainless steel. The temperature is adjusted in a heating furnace 126 provided with a belt 124 and a belt heater roll 122.
  • seat 129 as a melt-extrusion molded article is obtained by cut
  • FIG. 1 when the breaking strength of the obtained sheet 129 was measured, the bending strength in the longitudinal direction (longitudinal direction) was 231 MPa, and the bending elastic modulus was 9.8 GPa. Further, the bending strength in the transverse direction (width direction) was 212 MPa, and the flexural modulus was 9.2 GPa.
  • Example 11 Using the hybrid pellet 1 of Example 1 described above, extrusion molding was performed at a discharge rate of 50 g / min using a melt extrusion pipe manufacturing apparatus 130 shown in FIG. 10 to produce a pipe having an inner diameter of 20 mm and an outer diameter of 25 mm. More specifically, in the melt extrusion pipe manufacturing apparatus 130 shown in FIG. 10, the resin material 114 extruded from the melt extrusion pipe die 131 in a molten state is supplied to the temperature adjustment water inlet 141 and the temperature adjustment water outlet 145. The shape is adjusted by a pipe sizing die 135 having a cooling part 139 that communicates with the cooling part 139 and cooled in a constant temperature water tank 147.
  • the melted extruded pipe 151 is obtained by cutting the cooled resin material 114 with the cutter 150 while continuously taking it with the take-up machine 149.
  • the obtained pipe 151 had a bending strength of 236 MPa and a bending elastic modulus of 9.6 GPa.
  • the cross-sectional shape of this pipe 151 is shown in FIG.
  • Example 12 Using the hybrid pellet 1 of Example 1 above, extrusion molding was performed at a discharge rate of 70 g / min using a melt extrusion solid molded product manufacturing apparatus 180 shown in FIG. 12 to produce a round bar having an outer diameter of 15 mm. More specifically, in the melt-extruded solid product manufacturing apparatus 180 shown in FIG. 12, the resin material 114 extruded from the melt-extruded real product die 185 in a molten state is a solid-molded product sizing die 187. Then, the shape is adjusted and cooled by a constant temperature water tank 147.
  • the cooled resin material 114 is cut by the cutter 150 while being continuously taken by the take-up machine 149, thereby obtaining the actual product 188 (round bar in this embodiment) during melt extrusion.
  • the other configuration of the manufacturing apparatus 180 is the same as that of the manufacturing apparatus 130 shown in FIG. 10, the same reference numerals as those in FIG. In this example, the obtained round bar 188 had a bending strength of 241 MPa and a bending elastic modulus of 9.9 GPa.
  • the cross-sectional shape of this round bar 188 is shown in FIG.
  • Example 13 Using the hybrid pellet 1 of Example 1 described above, extrusion molding was performed at a discharge rate of 70 g / min using the melt extrusion modified product manufacturing apparatus 190 shown in FIG. 14, and I-shaped, H-shaped, and T-shaped modified extruded products. Produced. More specifically, the resin material 114 extruded in the molten state from the melt-extruded profile die 191 in the melt-extruded profile manufacturing apparatus 190 shown in FIG. The shape is adjusted and cooled by the constant temperature water tank 147. Then, the cooled resin material 114 is cut by the cutter 150 while being continuously taken by the take-up machine 149, whereby a melt-extruded profile 194 is obtained.
  • FIG. 15 shows the cross-sectional shapes of an I-type variant 197, an H-type variant 198, and a T-type variant 199.
  • Example 14 Using the hybrid pellet 1 of Example 1 described above, extrusion molding was performed at a discharge rate of 30 g / min using a solidified extruded product manufacturing apparatus 210 shown in FIG. 16 to produce an extruded block having a width of 300 mm and a thickness of 100 mm. More specifically, in the solidified extrusion molded product manufacturing apparatus 210 shown in FIG. 16, the resin material 114 extruded in a molten state from the solidified extrusion die 212 is heated by a heating unit 213 provided with a heater 215.
  • the extrusion block 231 obtained by the manufacturing apparatus 210 was cut to produce a dumbbell piece having a measurement width of 10 ⁇ 0.5 mm and a measurement length of 80 ⁇ 2 mm.
  • the obtained dumbbell pieces had a bending strength of 275 MPa and a bending elastic modulus of 11.5 GPa.
  • the cross-sectional shape of the extrusion block 231 is shown in FIG.
  • Example 15 Using the hybrid pellet 1 of Example 1 described above, extrusion molding was performed at a discharge rate of 30 g / min using a round bar die in the solidified extrusion molded product manufacturing apparatus 210 shown in FIG. 16 to produce a ⁇ 150 mm round bar. .
  • the obtained round bar 232 had a bending strength of 265 MPa and a bending elastic modulus of 10.8 GPa.
  • the cross-sectional shape of the round bar 232 is shown in FIG.
  • Example 16 Using the hybrid pellet 1 made of nylon 66 and carbon fiber described in Example 2, as in Example 10, it was extruded at a discharge rate of 200 g / min in the melt-extruded sheet manufacturing apparatus 111 shown in FIG. A sheet having a width of 300 mm and a thickness of 0.6 mm was produced. The obtained sheet was free from spring back and voids, and had good shape and surface condition.
  • Example 17 Using the hybrid pellet 1 composed of PP and carbon fiber described in Example 3, as in Example 13, it was extruded at a discharge rate of 70 g / min in the melt-extruded profile manufacturing apparatus 190 shown in FIG. I-type, H-type, and T-type profile extrusions were produced. The obtained profile extrusion-molded product was free from spring back and voids, and had good shape and surface condition.
  • Example 18 Using the hybrid pellet 1 made of ABS and carbon fiber as described in Example 4, as in Example 11, it was extruded at a discharge rate of 50 g / min using a melt-extruded pipe manufacturing apparatus 130 shown in FIG. A pipe having a diameter of 21 mm and an outer diameter of 25 mm was produced. The obtained pipe was free from springback and voids, and had good shape and surface condition.
  • Example 19 Using the hybrid pellet 1 made of PPS and carbon fiber described in Example 5, as in Example 10, the melt-extruded sheet manufacturing apparatus 111 shown in FIG. A sheet having a thickness of 300 mm and a thickness of 0.5 mm was produced. The obtained sheet was free from spring back and voids, and had good shape and surface condition.
  • Example 20 Using the melt-extruded sheet of Example 10 as an intermediate molded body, a sheet was prepared by a hot press molding method as shown in FIG. Specifically, first, the melt-extruded sheet 129 obtained in Example 10 was cut with a width of 300 mm and a length of 1200 mm to prepare a sheet 129a. Then, as shown in FIG. 18 (a), a total of 16 sheets 129a are laminated in four layers, and the sheets are arranged so that the sheets of each layer intersect 90 degrees with the other adjacent sheets. Thus, a four-layer laminate 300 shown in FIG. As shown in FIG.
  • this laminate 300 is placed in a mold comprising a concave mold 301 and a convex mold 302 and provided with a heater 305 and a water cooling tube 306, as shown in FIG. 18 (d).
  • pressurization was performed for 5 minutes under conditions of a mold temperature of 250 ° C. and a pressure of 20 MPa.
  • die was opened as shown in FIG.18 (e), and the hot press molding sheet
  • the dimensions of the obtained hot press-formed sheet 308 were 1200 mm in both length and width, and the thickness was 1.19 mm.
  • Example 21 Using the melt-extruded sheet of Example 10 as an intermediate molded body, a molded product was prepared by a hot press molding method as shown in FIG. Specifically, first, the melt-extruded sheet 129 obtained in Example 10 was cut with a width of 300 mm and a length of 300 mm to create a sheet 129b shown in FIG. As shown in FIG. 19 (b), it was put in a single die having a heater 305 and a water cooling tube 306.
  • This mold was composed of a box-shaped concave mold 320 and a convex mold 321 having a shape corresponding to the box-shaped concave mold 320, and the dimensions of the molding part were 10 mm high, 150 mm wide, and 170 mm long. Then, as shown in FIG.19 (c), the metal mold
  • a hot press-formed product 325 having a shape was obtained.
  • the dimensions of the obtained hot press-formed product 325 were 10 mm in height, 150 mm in width, 170 mm in length, and the thickness was 0.25 mm.
  • Example 22 Using the hot press-molded sheet of Example 20 as an intermediate molded body, a molded product was prepared by a hot press molding method as shown in FIG. Specifically, first, the hot press-formed sheet 308 obtained in Example 20 was cut into a width of 300 mm and a length of 300 mm to create a sheet 308a shown in FIG. As shown in FIG. 20 (b), it was put in a single die having a heater 305 and a water cooling tube 306. This mold was composed of a box-shaped concave mold 320 and a convex mold 321 having a shape corresponding to the box-shaped concave mold 320, and the dimensions of the molding part were 10 mm high, 150 mm wide, and 170 mm long.
  • the mold was closed and pressurized for 5 minutes under the conditions of a mold temperature of 250 ° C. and a pressure of 15 MPa. And after cooling a metal mold
  • the obtained hot press-formed product 326 had a height of 10 mm, a width of 150 mm, a length of 170 mm, and a thickness of 1.04 mm.
  • Example 23 Using the hot press-molded sheet of Example 20 as an intermediate molded body, a molded product was prepared by a hot press molding method as shown in FIG. Specifically, first, the hot press-molded sheet 308 obtained in Example 20 was cut into a width of 300 mm and a length of 300 mm to produce a sheet 308a shown in FIG. And after heating this sheet
  • die was closed and pressurization was performed for 2 minutes with the pressure of 20 MPa.
  • the taken-out hot press molded object 327a was deburred, and the box-shaped hot press molded product 326a shown in FIG.21 (e) was obtained.
  • the dimensions of the obtained hot press-formed product 326a were 10 mm in height, 150 mm in width, 170 mm in length, and 1.09 mm in thickness.
  • Example 24 Using the hot press-molded sheet of Example 20 as an intermediate molded body, a molded product was prepared by a vacuum molding method as shown in FIG. Specifically, first, the hot press-formed sheet 308 obtained in Example 20 was cut into a width of 300 mm and a length of 300 mm to create a sheet 308a shown in FIG. For 5 minutes at 245 ° C. Subsequently, as shown in FIG. 22B, the sheet 308a is put into a single-piece vacuum forming die 342 provided with a suction hole 334, a suction port 335, and a heater 305, and the die temperature is 80 ° C.
  • vacuum suction was performed at the suction hole 334 for 2 minutes under the condition of a pressure of 1.0 ⁇ 10 ⁇ 4 MPa.
  • the dimensions of the molding part of this mold were 8 mm high, 140 mm wide, and 170 mm long.
  • the deburring of the picked-up vacuum forming body 346 was performed, and the box-shaped vacuum-formed product 347 shown in FIG.22 (e) was obtained.
  • the obtained vacuum-formed product 347 had a height of 10 mm, a width of 150 mm, a length of 170 mm, and a thickness of 0.67 mm.
  • Example 25 Using the hot press-molded sheet of Example 20 as an intermediate molded body, a molded product was produced by a blow molding method as shown in FIG. Specifically, first, the hot press molded sheet 308 obtained in Example 20 was cut into a width of 300 mm and a length of 500 mm to prepare a sheet 308b. Subsequently, as shown in FIG. 23 (a), two sheets 308b are fixed to the sheet fixture 351 to create a sheet holder 352, and this sheet holder 352 is placed at 245 ° C. for 5 minutes with an infrared heater. After heating, it was placed in a mold heated to 155 ° C. As shown in FIG.
  • this mold was composed of a concave upper mold 354 and a convex lower mold 353, and was provided with a blow port 355, a blow hole 356 and a heater 305.
  • the dimensions of the shaping part of the upper mold 354 were 30 mm in height, 110 mm in width, and 160 mm in length
  • the dimensions of the shaping part in the lower mold 353 were 10 mm in height, 110 mm in width, and 160 mm in length.
  • FIGS. 23 (e) and 23 (f) are obtained.
  • the resulting blow molded article 358 had a height of 20 mm, a width of 110 mm, a length of 160 mm, and a thickness of 0.51 mm. Further, as can be seen from the cross-sectional view of the blow molded product 358 shown in FIG. 23 (f), the inside of the blow molded product 358 was hollow.
  • Example 26 Using the melt-extruded sheet of Example 10 as an intermediate molded body, a molded product was prepared by a hot press molding method as shown in FIG. Specifically, first, the melt-extruded sheet 129 obtained in Example 10 was cut into a width of 300 mm and a length of 1200 mm to prepare a sheet 129a. Then, as shown in FIG. 24 (a), a total of eight sheets 129a are stacked in two layers of four sheets, and the sheets of each layer are arranged so that the upper sheet intersects the lower sheet by 90 degrees. A glass fiber fabric 371 having a basis weight of 110 g / m 2 and a thickness of 0.15 mm was placed on the uppermost surface to form a three-layer laminate 372.
  • this laminate 372 is placed in a mold comprising a concave mold 301 and a convex mold 302 and having a heater 305 and a water-cooled tube 306.
  • the mold was pressurized for 5 minutes under the conditions of a mold temperature of 250 ° C. and a pressure of 15 MPa.
  • die is opened as shown in FIG.24 (e), and the heat
  • a press-formed sheet 375 was obtained.
  • the dimensions of the obtained hot press-formed sheet 375 were 1200 mm in both length and width, and the thickness was 0.72 mm.
  • Example 27 Using the melt-extruded sheet of Example 10 as an intermediate molded body, a molded product was produced by a hot press molding method as shown in FIG. Specifically, first, the melt-extruded sheet 129 obtained in Example 10 was cut into a width of 300 mm and a length of 1200 mm to prepare a sheet 129a. Then, as shown in FIG. 25 (a), a total of eight sheet materials 129a are laminated in four layers, and the sheet materials of each layer are arranged so that the upper sheet intersects the lower sheet by 90 degrees. At the same time, a thermoplastic resin sheet 377 made of polypropylene and having a thickness of 0.50 mm was disposed between the two layers to form a three-layer laminate 378.
  • a thermoplastic resin sheet 377 made of polypropylene and having a thickness of 0.50 mm was disposed between the two layers to form a three-layer laminate 378.
  • this laminated body 372 is placed in a mold that includes a concave mold 301 and a convex mold 302 and is provided with a heater 305 and a water-cooled tube 306.
  • the mold was pressurized for 5 minutes under the conditions of a mold temperature of 250 ° C. and a pressure of 10 MPa.
  • die is opened as shown in FIG.25 (e), and as shown in FIG.25 (f), hot press molding which consists of a carbon fiber composite material and a polypropylene.
  • Sheet 379 was obtained.
  • the dimensions of the obtained hot press-formed sheet 379 were 1200 mm in both length and width, and the thickness was 1.05 mm.
  • Example 28 Using the hot press-molded sheet of Example 26 as an intermediate molded body, as shown in FIG. 26, a molded product was prepared by a hot press molding method. Specifically, first, the hot press-formed sheet 375 obtained in Example 26 was placed in a three-piece mold having a heater 305 and a water-cooled tube 306 as shown in FIG. This mold was composed of an upper mold 391 and a lower mold 392 corresponding to the upper mold 391, and the dimensions of the molded part were 5 mm in height, 140 mm in width, and 200 mm in length. Then, as shown in FIG.26 (b), the metal mold
  • a box-shaped hot press-formed product 393 was obtained.
  • the obtained hot press-formed product 393 had a height of 5 mm, a width of 140 mm, a length of 250 mm, and a thickness of 0.89 mm.
  • Example 29 Using the melt-extruded sheet of Example 10 as an intermediate molded product, a molded product was molded in substantially the same manner as in Example 27. Specifically, first, the melt-extruded sheet 129 obtained in Example 10 was cut into a width of 300 mm and a length of 1200 mm to prepare a sheet. Then, a total of 8 sheets are laminated in 4 layers, and each sheet is arranged so that the upper sheet intersects with the lower sheet by 90 degrees, and between these two layers, the basis weight is 90 g / A carbon fiber woven fabric having a thickness of 0.15 mm at m 2 was disposed to prepare a three-layer laminate.
  • This laminate was put into a mold composed of a concave mold and a convex mold, the mold was closed, and then pressed for 5 minutes under the conditions of a mold temperature of 250 ° C. and a pressure of 20 MPa. And after cooling a metal mold
  • the dimensions of the obtained hot press-formed sheet were 1200 mm in both length and width, and the thickness was 0.71 mm.
  • Example 30 Using the hot press-molded sheet of Example 29 as an intermediate molded body, a molded product was molded by substantially the same method as in Example 24. Specifically, first, the hot press-formed sheet obtained in Example 29 was cut into a width of 300 mm and a length of 300 mm to prepare a sheet, and this sheet was formed at 245 ° C. at 5 ° C. with two upper and lower electric infrared heaters. Heated for minutes. Subsequently, this sheet was put into a single vacuum forming mold, and after forming the sheet at a mold temperature of 80 ° C., vacuum suction was performed for 2 minutes under the condition of a pressure of 1.0 ⁇ 10 ⁇ 4 MPa. went.
  • the dimensions of the molding part of the mold were 8 mm high, 140 mm wide, and 170 mm long. And after opening a metal mold
  • Example 31 Using the hot press-molded sheet of Example 27 as an intermediate molded product, a molded product was produced by a method substantially similar to that of Example 25. Specifically, first, the hot press-formed sheet obtained in Example 20 was cut into a width of 300 mm and a length of 500 mm to prepare a sheet, and the two sheets were fixed to a sheet fixture and a sheet holder. It was created. The sheet holder was heated with an infrared heater at 245 ° C. for 5 minutes, and then placed in a mold and the mold was closed. Subsequently, air was flown for 2 minutes at a pressure of 1.5 MPa under a mold temperature of 80 ° C. to perform molding.
  • the taken-out blow molded object was deburred and the hollow and box-shaped blow molded product was obtained.
  • the dimensions of the obtained blow-molded product were a height of 20 mm, a width of 110 mm, a length of 160 mm, and a thickness of 0.50 mm.
  • the inside of the obtained blow molded product was hollow.
  • Example 32 The profile extrudate I type 197 obtained in Example 17 was heated to 200 ° C. in an oven and bent. As shown in FIG. 27, an S-shaped bent product 401 and a square bent product 402 could be obtained.
  • Example 1 the test conditions in each comparative example are basically the same as those in Example 1 unless otherwise specified.
  • the manufacturing method of FIG. 7 which is a manufacturing method of pellets having a core-sheath structure in the prior art
  • the first thermoplastic resin B1 made of nylon 6 is discharged from the extruder 60 to a flat belt-like carbon fiber roving at a temperature of 275 ° C.
  • a core-sheath type carbon fiber-containing resin pellet 6 having a core-sheath structure in which a core made of carbon fiber is covered with nylon 6 is obtained.
  • the content rate of the carbon fiber in the obtained core-sheath-type carbon fiber containing resin pellet 6 is 15%.
  • the pellet was used for injection molding to produce a dumbbell piece similar to that in Example 1.
  • the resulting dumbbell pieces had a bending strength of 188 MPa and a flexural modulus of 8.0 GPa.
  • the pellet 5 having the three-layer structure shown in FIG. 3 is manufactured by using the die 70 of FIG. . More specifically, in the die 70, the molten first thermoplastic resin 61 is discharged to the carbon fiber roving 46 through the introduction hole 72a, and the surface of the carbon fiber roving 46 is covered with the first thermoplastic resin 61. To do. Subsequently, the melted second thermoplastic resin 71 is discharged to the carbon fiber roving 46 through the introduction hole 72 b, and the surface of the first thermoplastic resin 61 is covered with the second thermoplastic resin 71.
  • the resin B1 made of nylon 6 is used as the first thermoplastic resin
  • the resin B2 made of nylon 6 is used as the second thermoplastic resin
  • the temperature in the die 70 is set to 275 ° C.
  • a pellet 5 having the three-layer structure shown in FIG. 3 was obtained.
  • the content rate of the carbon fiber in the obtained core-sheath-type carbon fiber resin pellet 5 is 15%.
  • the pellet was used for injection molding to produce a dumbbell piece similar to that in Example 1.
  • the obtained dumbbell pieces had a bending strength of 210 MPa and a flexural modulus of 9.3 GPa.
  • Comparative Example 6 The pellet 6 described in Comparative Example 1 above was extruded at a discharge rate of 50 g / min using the melt extrusion pipe manufacturing apparatus 130 shown in FIG. 10 to produce a pipe having an inner diameter of 20 mm and an outer diameter of 25 mm. As a result, springback due to carbon fiber occurred, and a desired pipe could not be produced.
  • Comparative Example 7 Using pellets 6 described in Comparative Example 1 above, extrusion molding was performed at a discharge rate of 70 g / min using a melt extrusion solid molded product manufacturing apparatus 180 shown in FIG. 12, and an attempt was made to produce a round bar having an outer diameter of 15 mm. However, the spring back by carbon fiber generate
  • Comparative Example 14 Using the pellet 5 described in Comparative Example 2, extrusion molding was performed at a discharge rate of 70 g / min using the melt extrusion profile manufacturing apparatus 190 shown in FIG. 14, and I-type, H-type, and T-type profile extrusion-molded products. Although an attempt was made to produce the molded article, the resulting molded article had many voids in the cross section, and could not be stably and continuously molded.
  • Comparative Example 15 The pellet 5 described in Comparative Example 2 was extruded at a discharge rate of 30 g / min using a solidified extruded product manufacturing apparatus 210 shown in FIG. 16 to produce an extruded block having a width of 300 mm and a thickness of 100 mm.
  • a dumbbell piece with a measurement width of 10 ⁇ 0.5 mm and a measurement length of 80 ⁇ 2 mm by cutting this extruded block.
  • there is a void in the block and it is possible to produce a desired dumbbell piece. could not.
  • Comparative Example 16 The pellet 5 described in Comparative Example 2 was extruded at a discharge rate of 30 g / min using a solidified extruded product manufacturing apparatus 210 shown in FIG. 16 to produce a ⁇ 150 mm round bar. When the obtained round bar was examined, voids were generated in the cross section.
  • Extrusion block of 300 mm width and 100 mm thickness is extruded using non-reinforced pellets made of nylon 6 and containing no reinforcing fibers, with a solidified extruded product manufacturing apparatus 210 shown in FIG. 16 at a discharge rate of 30 g / min. Was made. Then, the extruded block was cut to produce a dumbbell piece, and the strength was measured. As a result, the bending strength was 106 MPa, and the bending elastic modulus was 2.7 GPa.
  • the carbon fiber composite material and molded product thereof according to the present invention are suitable for all uses where high strength and excellent workability are required, and as mass-produced products such as cushioning materials, heat insulating materials, reinforcing materials, seat belts, and pipes. In addition to the above-mentioned applications, it is also suitable for applications such as samples before mold manufacture and products for the semiconductor industry, such as products for high-mix low-volume production that require high accuracy.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Reinforced Plastic Materials (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention porte sur un procédé pour produire un matériau composite à fibre de carbone, qui est obtenu en fondant des granules ayant une structure âme-revêtement dans laquelle le composant âme comprend de la fibre de carbone et le composant revêtement comprend une première résine thermoplastique, avec une seconde résine thermoplastique, et en malaxant les granules fondues et la seconde résine thermoplastique à une température prédéterminée. L'invention porte également sur un procédé pour produire un article moulé par fusion et moulage du matériau composite à fibre de carbone produit à l'aide du procédé de production de cette description. Elle porte en outre sur un matériau composite à fibre de carbone caractérisé en ce qu'il comprend une première résine thermoplastique, une seconde résine thermoplastique et de la fibre de carbone et qui a une structure dans laquelle une phase île constituée de la première résine thermoplastique est dispersée dans une phase mer constituée de la seconde résine thermoplastique ; ainsi que sur un article moulé formé par moulage de ce matériau. Selon la présente invention, il est possible de créer un matériau composite à fibre de carbone qui possède une résistance physique améliorée, qui peut être post-traité facilement et qui est optimisé pour la fabrication d'un article moulé à haute rigidité, ainsi qu'un article moulé formé par moulage de ce matériau et des procédés respectifs pour produire le matériau composite à fibre de carbone et l'article moulé.
PCT/JP2013/064655 2012-06-11 2013-05-27 Matériau composite à fibre de carbone, article moulé formé à l'aide de celui-ci et procédés de production respectifs WO2013187220A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2013534875A JP5608818B2 (ja) 2012-06-11 2013-05-27 炭素繊維複合材料およびそれを用いてなる成形品、ならびにそれらの製造方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2012131667 2012-06-11
JP2012-131667 2012-06-11

Publications (1)

Publication Number Publication Date
WO2013187220A1 true WO2013187220A1 (fr) 2013-12-19

Family

ID=49758050

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2013/064655 WO2013187220A1 (fr) 2012-06-11 2013-05-27 Matériau composite à fibre de carbone, article moulé formé à l'aide de celui-ci et procédés de production respectifs

Country Status (3)

Country Link
JP (1) JP5608818B2 (fr)
TW (1) TW201406842A (fr)
WO (1) WO2013187220A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016064607A (ja) * 2014-09-25 2016-04-28 トヨタ自動車株式会社 繊維強化樹脂成形体の製造方法
FR3030549A1 (fr) * 2014-12-22 2016-06-24 Rhodia Operations Melange de polyamides a fluidite amelioree
JP2020528845A (ja) * 2017-07-24 2020-10-01 エアライト、インコーポレイテッド． 繊維強化成形コンパウンド並びにその形成及び使用方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP7096036B2 (ja) * 2018-03-29 2022-07-05 東レ株式会社 熱可塑性樹脂炭素繊維複合材料の製造方法
JP6748974B2 (ja) * 2019-06-13 2020-09-02 パナソニックＩｐマネジメント株式会社 成形材料、成形体、自転車、成形体の製造方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002088259A (ja) * 2000-09-18 2002-03-27 Toray Ind Inc 成形材料その製造方法およびその成形品
JP2004231910A (ja) * 2003-02-03 2004-08-19 Toyo Ink Mfg Co Ltd 繊維含有熱可塑性樹脂組成物及びその利用
WO2010074120A1 (fr) * 2008-12-25 2010-07-01 東レ株式会社 Composition de résine propylène renforcée par des fibres

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05124036A (ja) * 1991-03-08 1993-05-21 Asahi Fiber Glass Co Ltd 繊維補強樹脂体の製造法
JP3774959B2 (ja) * 1996-11-06 2006-05-17 東レ株式会社 成形材料およびその製造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002088259A (ja) * 2000-09-18 2002-03-27 Toray Ind Inc 成形材料その製造方法およびその成形品
JP2004231910A (ja) * 2003-02-03 2004-08-19 Toyo Ink Mfg Co Ltd 繊維含有熱可塑性樹脂組成物及びその利用
WO2010074120A1 (fr) * 2008-12-25 2010-07-01 東レ株式会社 Composition de résine propylène renforcée par des fibres

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016064607A (ja) * 2014-09-25 2016-04-28 トヨタ自動車株式会社 繊維強化樹脂成形体の製造方法
US9849614B2 (en) 2014-09-25 2017-12-26 Toyota Jidosha Kabushiki Kaisha Production method of producing fiber-reinforced resin molding
FR3030549A1 (fr) * 2014-12-22 2016-06-24 Rhodia Operations Melange de polyamides a fluidite amelioree
WO2016102507A1 (fr) * 2014-12-22 2016-06-30 Rhodia Operations Melange de polyamides a fluidite amelioree
KR20170097095A (ko) * 2014-12-22 2017-08-25 로디아 오퍼레이션스 개선된 유동성을 가진 폴리아미드 혼합물
RU2692368C2 (ru) * 2014-12-22 2019-06-24 Родиа Операсьон Смесь полиамидов с улучшенной текучестью
US10723879B2 (en) 2014-12-22 2020-07-28 Rhodia Operations Polyamide mixture having improved fluidity
KR102454005B1 (ko) 2014-12-22 2022-10-14 로디아 오퍼레이션스 개선된 유동성을 가진 폴리아미드 혼합물
JP2020528845A (ja) * 2017-07-24 2020-10-01 エアライト、インコーポレイテッド． 繊維強化成形コンパウンド並びにその形成及び使用方法
JP7156766B2 (ja) 2017-07-24 2022-10-19 エアライト、インコーポレイテッド． 繊維強化成形コンパウンド並びにその形成及び使用方法

Also Published As

Publication number Publication date
JP5608818B2 (ja) 2014-10-15
JPWO2013187220A1 (ja) 2016-02-04
TW201406842A (zh) 2014-02-16

Similar Documents

Publication Publication Date Title
JP5608818B2 (ja) 炭素繊維複合材料およびそれを用いてなる成形品、ならびにそれらの製造方法
JP2569380B2 (ja) 繊維強化成形品
JP7340521B2 (ja) 連続繊維補強熱可塑性樹脂複合材料及びその製造方法
CN107735433A (zh) 纤维强化树脂片材的制造方法
JP6085798B2 (ja) ３次元形状成形用複合材及びその製造方法
US10988603B2 (en) Molded resin strand
CN109715385B (zh) 层叠基材及其制造方法
JP2011073436A (ja) 中間製品および中間製品複合体
JPS6337694B2 (fr)
US11332627B2 (en) Filament resin molded article
JP2020528845A (ja) 繊維強化成形コンパウンド並びにその形成及び使用方法
KR20140107304A (ko) 성형체의 제조 방법 및 성형체
US11826940B2 (en) Production method for fiber-reinforced thermoplastic resin composite material, production method for fiber-reinforced thermoplastic resin tape, production method for press-molding material, production method for molded article, unidirectional prepreg, and molded article
US20200114544A1 (en) Method and Apparatus for Manufacturing Fiber Composite Parts Utilizing Direct, Continuous Conversion of Raw Materials
WO2012133013A1 (fr) Pièce moulée en couches de résine thermoplastique renforcée de fibres
JP3620103B2 (ja) 樹脂被覆補強繊維糸の製造方法
KR101517477B1 (ko) 직접함침법 및 더블 벨트 프레스 장치를 이용한 연속 섬유 강화 폴리유산 복합소재의 제조방법 및 제조장치
WO2016134829A1 (fr) Système de traitement et procédé de fabrication d'un élément en matière plastique renforcée de fibres
CN116323129A (zh) 纤维增强树脂拉拔成型体及其制造方法
JP2017160316A (ja) 炭素繊維複合材料およびその製造方法
JP5225260B2 (ja) 長繊維強化熱可塑性樹脂ストランドの製造装置及び製造方法
JP5958360B2 (ja) Ｆｒｐシートの製造方法
KR101462881B1 (ko) 장섬유강화 열가소성 수지 제조장치
JP2013193243A (ja) 繊維強化樹脂成形体の製造方法
JP7096036B2 (ja) 熱可塑性樹脂炭素繊維複合材料の製造方法

Legal Events

Date Code Title Description
ENP Entry into the national phase

Ref document number: 2013534875

Country of ref document: JP

Kind code of ref document: A

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 13803494

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 13803494

Country of ref document: EP

Kind code of ref document: A1