WO2020009125A1 - Cfrp sheet, laminated body using cfrp sheet, and cfrp sheet production method - Google Patents

Cfrp sheet, laminated body using cfrp sheet, and cfrp sheet production method Download PDF

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Publication number
WO2020009125A1
WO2020009125A1 PCT/JP2019/026365 JP2019026365W WO2020009125A1 WO 2020009125 A1 WO2020009125 A1 WO 2020009125A1 JP 2019026365 W JP2019026365 W JP 2019026365W WO 2020009125 A1 WO2020009125 A1 WO 2020009125A1
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Prior art keywords
sheet
layer
cfrp
sheet piece
resin
Prior art date
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PCT/JP2019/026365
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French (fr)
Japanese (ja)
Inventor
金森尚哲
兼岩秀和
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フクビ化学工業株式会社
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Application filed by フクビ化学工業株式会社 filed Critical フクビ化学工業株式会社
Priority to CN201980044180.4A priority Critical patent/CN112399917B/en
Priority to JP2020529015A priority patent/JP7118149B2/en
Publication of WO2020009125A1 publication Critical patent/WO2020009125A1/en

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    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction

Definitions

  • the present invention relates to an improvement in a CFRP sheet, and more particularly, to a CFRP sheet excellent in design, a laminate using the same, and a method for efficiently producing the CFRP sheet.
  • CFRP carbon fiber reinforced plastic
  • a UD sheet in which carbon fiber bundles arranged and aligned in the length direction are bonded and integrated with a matrix resin is finely cut into strips, and the cut strip-shaped UD sheet pieces are arranged in a two-dimensional direction.
  • a CFRP sheet formed into a sheet by being integrated by a hot press has also been developed (for example, see Patent Document 1).
  • CFRP sheet has an appearance in which strip-shaped (rectangular) UD sheet pieces are merely arranged on the surface, and there is no significant difference in the shape of each UD sheet piece. It was easy to be a monotonous design. For this reason, CFRP sheets have rarely been used for applications such as decorative sheets that require design properties.
  • the present invention has been made in view of the above-described problems, and a purpose thereof is to provide a CFRP sheet having not only excellent mechanical strength such as tensile strength but also excellent design of a visible surface, and An object of the present invention is to provide a laminated body used and a method for efficiently producing the CFRP sheet.
  • a CFRP sheet is formed by forming a transparent resin layer C outside the surface layer of the CFRP layer S, and the CFRP layer S is formed by forming continuous fibrous carbon fibers FF in the longitudinal direction.
  • each of PP is characterized in that the average thickness is smaller than that of the UD sheet piece Q of the back surface layer or the intermediate layer, and that at least a part includes a non-rectangularly distorted sheet piece.
  • non-rectangular shape refers to the difference between the maximum value and the minimum value of the width dimension (dimension in the direction perpendicular to the length direction of the carbon fiber) of the UD sheet piece is the maximum value of the width dimension.
  • the present invention provides a CFRP sheet in which a transparent resin layer C is formed outside a surface layer of the CFRP layer S, wherein the CFRP layer S aligns continuous fibrous carbon fibers FF in a length direction.
  • a large number of UD sheet pieces, which are bonded and integrated with the matrix resin M in an arranged state, are arranged in a two-dimensional direction so that the fiber directions of the respective sheet pieces are randomly oriented, and the respective sheet pieces overlap each other.
  • the UD sheet pieces P and Q of the surface layer and the back surface layer of the CFRP layer S may include non-rectangularly distorted sheet pieces while being bonded by the matrix resin M in the folded state. .
  • the ratio of the non-rectangularly distorted UD sheet piece P in the surface layer of the CFRP layer S is 30% or more (preferably 50% or more), and the unique appearance is excellent in design.
  • a CFRP sheet can be formed.
  • the average area per one UD sheet piece P in the surface layer of the CFRP layer S is made larger than the average area of the UD sheet piece Q of the back layer or the intermediate layer to thereby reduce the surface layer.
  • the distortion of the shape of the UD sheet piece P can be increased to enhance the design effect.
  • the ratio of the unraveled portion L in which the parallel carbon fibers are partially separated from each other in the UD sheet piece P of the surface layer of the CFRP layer S is made larger than that of the UD sheet piece Q of the back layer or the intermediate layer.
  • the UD sheet piece P of the surface layer can be formed when the transparent resin layer C is formed. Can be easily unraveled.
  • a laminate having a unique appearance and excellent design can be formed by laminating and integrating the above CFRP sheet on the surface of the same material or a different material.
  • a large number of UD sheet pieces arranged in a two-dimensional direction and a resin film as a material of a transparent resin layer are roll-formed and temporarily bonded, or two-dimensionally.
  • the intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated by coating the molten resin as a material of the transparent resin layer on a large number of UD sheet pieces arranged in May be further hot pressed to deform the UD sheet piece of the surface layer.
  • the pressing force of the hot press on the intermediate sheet material the pressing force of the roll forming when the UD sheet piece and the resin film are temporarily bonded, or the hot pressing of the UD sheet piece coated with the molten resin are used. It is preferable that the pressure is larger than the pressing force.
  • a continuous fiber carbon fiber and a thermoplastic resin are roll-formed to form a UD sheet by bonding carbon fibers to each other.
  • the UD sheet pieces produced by cutting this UD sheet into a rectangular shape are arranged in a two-dimensional direction on a resin film as a material of a transparent resin layer, or formed into a large number of UD sheet pieces arranged in a two-dimensional direction. It is also possible to adopt a method in which the UD sheet piece of the surface layer is distorted by coating the molten resin which is the material of the transparent resin layer and performing heat compression molding.
  • the pressing force of the heat compression molding on the resin film and the UD sheet piece or the pressing force of the heat compression molding on the UD sheet piece coated with the molten resin is determined by the pressing force of the roll forming during the production of the UD sheet. Preferably, it is larger.
  • the basis weight of the resin film is 5% or more of the basis weight of the entire UD sheet piece in order to enhance the design of the surface.
  • a large number of UD sheet pieces are bonded in a state in which the fiber direction of each sheet piece is randomly oriented, and in a state where the sheet pieces are arranged in a two-dimensional direction so that the sheet pieces overlap each other, and the CFRP sheet is bonded.
  • a unique appearance can be imparted to the sheet surface by forming and including a non-rectangularly distorted UD sheet piece in the surface layer.
  • the back layer or the intermediate layer of the CFRP sheet is formed of a rectangular UD sheet piece having a thickness greater than that of the UD sheet piece of the surface layer and having a uniform shape, There is no concern that the tensile strength or the like is greatly impaired, and both design properties and mechanical strength can be achieved.
  • CFRP sheet that can be used as a reinforcing sheet or the like without any problem and can be suitably used as a surface sheet or the like requiring a design property can be provided. Very expensive.
  • CFRP sheet [1] Basic Configuration of CFRP Sheet First, in the present embodiment, as shown in FIG. 1, a CFRP layer S and a transparent resin layer C are formed outside a visible surface side surface layer to form a sheet body. ing. Further, as shown in FIGS. 2A, 2B, and 2C, the CFRP layer S has a large number of UD sheet pieces P and Q arranged in a two-dimensional direction such that the sheet pieces overlap each other. Carbon fiber materials in which the fiber directions of Q are randomly oriented (arranged so that the fiber directions of the UD sheet pieces are scattered) are formed by bonding and integrating with a matrix resin M.
  • the UD sheet pieces P and Q of the CFRP layer S are arranged in a matrix resin in a state where continuous fibrous carbon fibers FF are aligned in the length direction as shown in FIGS.
  • the one integrated with M is used.
  • the rear layer or the intermediate layer which is the invisible surface of the CFRP layer S, is configured by arranging rectangular UD sheet pieces Q, Q,... Shown in FIG. 3B, while the surface layer of the CFRP layer S is
  • the UD sheet pieces PP having an average thickness smaller than the UD sheet piece Q of the back layer or the intermediate layer shown in FIG. 3A are arranged side by side, and at least a part thereof includes a non-rectangularly distorted sheet piece. I am trying to be.
  • the UD sheet pieces Q having relatively large thicknesses of the back layer and the intermediate layer ensure the mechanical strength of the CFRP layer S while having a relatively small thickness and a small shape.
  • the UD sheet pieces PP having an uneven surface layer a unique appearance can be given to the sheet body as shown in FIG. 2 (b).
  • the smoothness of the surface of the sheet body can be improved by the transparent resin layer C formed outside the surface layer of the CFRP layer S, and the protective effect and the optical visual effect of the CFRP layer S can be imparted. .
  • the polyamide resin (nylon resin) is used in the present embodiment for the matrix resin M of the CFRP layer S, but the present invention is not limited to this, and the carbon fiber material is impregnated.
  • Other thermoplastic resins having properties acrylic resin, polyester, polyolefin, polystyrene, polycarbonate, ABS resin, polyetherimide, fluororesin, polyphenylene sulfide, etc.
  • thermosetting resins can also be used.
  • thermoplastic resin having adhesiveness to the thermoplastic resin of the transparent resin layer C is added to the matrix resin of the CFRP layer S. Is used, the UD sheet piece P of the surface layer can be easily unraveled during hot pressing.
  • Shape of UD sheet piece [4-1] Shape of UD sheet piece of surface layer Regarding the UD sheet piece P of the surface layer of the CFRP layer S, in this embodiment, a non-rectangular shape is used in order to enhance the design effect.
  • the ratio of the UD sheet piece P distorted in shape is set to 30% or more.
  • FIGS. 3 (a) are shown as UD sheet piece difference between the maximum value X 1 and the minimum value X 2 of the linear dimension of more than 10% of the maximum value X 1 of that the size, or refers to what the difference between the maximum value Y 1 and the minimum value Y 2 of the width is equal to or more than 10% of the maximum value Y 1.
  • the average thickness of the UD sheet piece Q of the back layer or the intermediate layer is set so that the shape of the UD sheet piece P of the surface layer becomes large. About half of that.
  • the average value of the maximum value Y 1 of the width of the UD sheet piece P as the average width so that the average width is equal to or greater than 1.5 times the average width of the UD sheet piece Q of the back layer or the intermediate layer I have to.
  • the average area of one UD sheet piece P of the surface layer is larger than the average area of the UD sheet piece Q of the inner layer.
  • the average width of the UD sheet piece P of the surface layer is set to be larger than the average width of the UD sheet piece Q of the back layer or the intermediate layer so that the shape of the UD sheet piece P of the surface layer increases. Is also getting bigger.
  • the ratio of the unraveled portion L in which the parallel carbon fibers F of the UD sheet piece P of the surface layer are partially separated from each other is made larger than that of the UD sheet piece Q of the back layer or the intermediate layer. .
  • width W 2 mm to 20 mm preferably 5 mm to 10 mm
  • length L 5 mm to 70 mm preferably 10 mm to 30 mm
  • ratio of width W to length L 1: 1 to 1 It is preferable to use a 1: 6 rectangular shape.
  • the direction along the length direction of the carbon fiber F is defined as the length direction of the UD sheet piece P, and the direction perpendicular to the direction is defined as the width direction.
  • the thickness of the UD sheet piece Q of the back layer or the intermediate layer is preferably in the range of 40 ⁇ m to 100 ⁇ m.
  • the average number of UD sheet pieces P and Q stacked in the CFRP layer S in the thickness direction is designed to be in a range of 5.0 to 8.0 sheets. However, any number of sheets can be designed according to the strength of the sheet body. Further, the thickness of the CFRP layer S is preferably designed in the range of 0.3 mm to 1.0 mm, but it can be formed in a thicker plate shape.
  • the surface layer serving as the visible surface of the CFRP layer S is formed on only one surface of the sheet body in the present embodiment, but is formed on both surfaces of the sheet body. Can also be formed. In that case, the CFRP layer S does not have a back surface layer, and is composed of only a surface layer and an intermediate layer. When the thickness of the CFRP layer S is very small, there may be a case where the intermediate layer does not exist and is composed of only the front surface layer and the back surface layer.
  • the material of the transparent resin layer C is a polyamide resin in the present embodiment, but is not limited to this.
  • Other thermoplastic resins having an impregnating property acrylic resin, PET, polyethylene, polystyrene, polycarbonate, ABS resin, polyetherimide, fluororesin, polyphenylene sulfide, etc.
  • thermosetting resins can also be used.
  • the transparent resin layer C includes not only a colorless and transparent layer but also a slightly colored translucent layer.
  • the basis weight of the resin film used as a material is determined with respect to the basis weight of the entire UD sheet piece.
  • the size is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%).
  • the weight per unit area of the resin film may be smaller than 5% of the total weight of the UD sheet piece.
  • the principle that the UD sheet piece of the surface layer is distorted is that, when the transparent resin melted into the fine irregularities on the surface of the CFRP layer flows (deforms) and enters, the carbon fiber of the UD sheet piece whose bonding force is weakened by heating. It is presumed to be caused by the movement of Further, the UD sheet pieces having weakened bonding force between the carbon fibers at the time of the hot pressing are crushed and the carbon fibers move in the width direction, so that the thickness of the UD sheet pieces of the surface layer becomes smaller than that of the back layer or the intermediate layer. And the width dimension of the UD sheet piece of the front surface layer is larger than the width dimension of the UD sheet piece of the back layer or the intermediate layer.
  • the pressing force of the hot press on the intermediate sheet material is made larger than the pressing force of the roll forming when the UD sheet piece and the resin film are temporarily bonded, so that the fluidity (deformability) of the transparent resin is increased. And the shape of the UD sheet piece of the surface layer is greatly distorted. Further, by increasing the pressing force of the hot press on the intermediate sheet material, it is possible to form more unraveled portions on the UD sheet piece of the surface layer.
  • thermoplastic resin film is used as the material of the transparent resin layer as described above.
  • a granular or short fiber thermoplastic resin is laminated and temporarily formed on a UD sheet piece.
  • the transparent resin layer can also be formed by bonding and hot pressing them.
  • the UD sheet piece of the surface layer can be distorted in the same manner as described above.
  • the basis weight of the resin film is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%) with respect to the basis weight of the entire UD sheet piece.
  • the method of producing the intermediate sheet material it is not always necessary to use a resin film, and a large number of UD sheet pieces arranged in a two-dimensional direction are coated with a molten resin as a material of a transparent resin layer and hot pressed. By doing so, it is possible to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated. In this case, it is preferable that the pressing force of the hot press on the intermediate sheet material is larger than the pressing force of the hot press on the UD sheet piece coated with the molten resin.
  • the flowability (deformability) of the transparent resin is increased by setting the pressure of the heat compression molding on the resin film and the UD sheet piece larger than the pressure of the roll molding at the time of producing the UD sheet.
  • the shape of the UD sheet piece of the surface layer is greatly distorted.
  • by increasing the pressing force of the heat compression molding on the resin film and the UD sheet piece it is possible to form more melting portions in the UD sheet piece of the surface layer.
  • a granular or short-fiber thermoplastic resin may be laminated instead of the thermoplastic resin film to form a transparent resin layer.
  • the UD sheet of the surface layer may be formed as described above.
  • the pieces can be distorted.
  • the basis weight of the resin film is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%) with respect to the basis weight of the entire UD sheet piece.
  • the heat compression molding does not necessarily require the use of a resin film, but may be performed on a multiplicity of layered UD sheet pieces coated with a molten resin as a material of a transparent resin layer.
  • the thickness of the CFRP layer S is preferably in the range of 0.1 mm to 0.2 mm (average number of UD sheet pieces P and Q: 2 to 4) so that the transparent resin enters the back layer.
  • the ratio of the UD sheet piece P distorted in a non-rectangular shape is preferably 30% or more (preferably 50% or more).
  • the seat body As described above, a unique appearance can be imparted to the seat body.
  • the smoothness of the surface of the sheet body can be improved by the transparent resin layer C formed outside the surface layer of the CFRP layer S, and the protective effect and the optical visual effect of the CFRP layer S can be provided.
  • Other configurations and manufacturing methods are the same as in the first embodiment.
  • the CFRP sheet of the first embodiment is laminated and integrated on the surface of a plastic material by hot pressing to form a laminate having excellent surface design (not shown).
  • a target for laminating the CFRP sheets not only a plastic material but also a different material such as a same kind of CFRP material or metal can be adopted.
  • Example 1 In this example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer in the CFRP sheet having the configuration of the first embodiment, and the method of the manufacturing method (i) was used. A sample was produced by the method described above.
  • the pressing force of the roll forming at the time of temporary bonding (the pressing force at the time of manufacturing the intermediate sheet material) is set to 0.2 to 0.4 MPa, and the pressing force of the hot press on the intermediate sheet material (from the intermediate sheet material to the sheet body). was 3 MPa.
  • Comparative Example 1 In the present example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer, respectively, in the CFRP sheet having the configuration of the first embodiment.
  • Example 1 ⁇ Test results> To summarize the test results of Example 1 and Comparative Examples 1 and 2, the sample of Example 1 was able to sufficiently improve the design, whereas the samples of Comparative Examples 1 and 2 were sufficiently improved in the design. could not be increased. A table summarizing the conditions and test results of each sample is shown below.
  • Example 1 In this example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer in the CFRP sheet having the configuration of the second embodiment, and the sample was produced by the production method (i). Was prepared.
  • a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.043 mm, and a Vf of 53% was used as a material.
  • the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa.
  • An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 43.3% was produced.
  • hot pressing was performed on the intermediate sheet material under the conditions of a mold temperature of 270 ° C., a pressing force of 3 MPa and a pressing time of 0.5 min, the mold temperature was 30 ° C., the pressing force was 5 MPa, and the pressing time was 3 min.
  • a cooling press was performed under the conditions to produce a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and Vf of 43.3%. As a result, a highly designable sample having a unique appearance was produced.
  • Example 2 In this example, in a CFRP sheet having the configuration of the second embodiment, a polyphenylene sulfide (PPS) resin was used as the matrix resin of the CFRP layer, and a polyamide resin was used as the thermoplastic resin of the transparent resin layer.
  • PPS polyphenylene sulfide
  • a sample was produced by the method described above.
  • a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.048 mm, and a Vf of 47% was used as a material.
  • the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa.
  • An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 35% was produced.
  • the mold temperature is 30 ° C., a pressing force of 5 MPa, and a pressing time of 3 min.
  • a cooling press was performed under the conditions to prepare a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and 35% Vf. As a result, a highly designable sample having a unique appearance was produced.
  • Example 3 In the present example, in the CFRP sheet having the configuration of the second embodiment, a polycarbonate resin (PC) is used as the matrix resin of the CFRP layer, and a polyamide resin is used as the thermoplastic resin of the transparent resin layer. A sample was prepared. In this embodiment, a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.048 mm, and a Vf of 47% was used as a material.
  • PC polycarbonate resin
  • a polyamide resin is used as the thermoplastic resin of the transparent resin layer.
  • the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa.
  • An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 35% was produced.
  • a cooling press was performed under the conditions to prepare a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and 35% Vf.
  • a highly designable sample having a unique appearance was produced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

[Problem] To provide a CFRP sheet that is not only excellent in terms of mechanical strength such as tensile strength, but also excellent in terms of visible surface design. [Solution] This CFRP sheet is constituted by forming a transparent resin layer C on the outer side of a surface layer from a CFRP layer S, wherein: the CFRP layer S is formed from multiple UD sheet pieces, each yielded from continuous fiber shaped carbon fibers F·F… arranged to be aligned in the length direction and in this state adhered to one another and turned into a single body with a matrix resin M, the UD sheet pieces being adhered by the matrix resin M while the fiber direction of each of the sheet pieces is in a randomly oriented state and the sheet pieces are in a state of being arranged in a two-dimensional orientation in such a manner as to overlap one another; and, in contrast to the UD sheet pieces P·Q… in the back surface layer or the middle layer of the CFRP layer S, which have a rectangular shape, the UD sheet pieces P·P… in the surface layer are constituted by including sheet pieces that are smaller in mean thickness than the UD sheet pieces Q in the back surface layer or the middle layer, and at least partially distorted into a non-rectangular shape.

Description

ＣＦＲＰシート、ＣＦＲＰシートを用いた積層体、及びＣＦＲＰシートの製造方法CFRP sheet, laminate using CFRP sheet, and method of manufacturing CFRP sheet
　本発明は、ＣＦＲＰシートの改良、詳しくは、意匠性に優れたＣＦＲＰシート、及びそれを用いた積層体、及び前記ＣＦＲＰシートの効率的な製造方法に関するものである。 The present invention relates to an improvement in a CFRP sheet, and more particularly, to a CFRP sheet excellent in design, a laminate using the same, and a method for efficiently producing the CFRP sheet.
　近年、強化繊維材料である炭素繊維とマトリックス樹脂から構成される炭素繊維強化プラスチック(ＣＦＲＰ)は、その優れた機能性から様々な用途で利用されている。またＣＦＲＰシートとしては、連続繊維状の炭素繊維束を縦横に配向したものや炭素繊維束を平織りしたものにマトリックス樹脂を含浸させて形成したものが広く知られている。 In recent years, carbon fiber reinforced plastic (CFRP) composed of carbon fiber and matrix resin, which are reinforced fiber materials, has been used in various applications due to its excellent functionality. Further, as the CFRP sheet, a sheet formed by impregnating a matrix resin into a sheet obtained by orienting a continuous fiber-like carbon fiber bundle in a vertical or horizontal direction or a sheet obtained by plain-weaving a carbon fiber bundle is widely known.
　しかしながら、上記従来のＣＦＲＰシートに関しては、ＣＦＲＰシートを熱プレス加工により任意の形状に成形する際、シート全体にわたって伸びる連続繊維状の炭素繊維束がプレス金型への追従性を阻害する要因となって賦形性の悪化を招き、結果として成形を行える形状が限定されてしまうという欠点があった。 However, regarding the conventional CFRP sheet, when the CFRP sheet is formed into an arbitrary shape by hot pressing, a continuous fibrous carbon fiber bundle extending over the entire sheet is a factor that hinders the ability to follow the press die. As a result, there is a drawback that the shapeability is deteriorated, and as a result, the shape in which molding can be performed is limited.
　そこで、従来においては、長さ方向に揃えて配列した炭素繊維束をマトリックス樹脂で接着一体化したＵＤシートを短冊状に細かく裁断し、この裁断した短冊状のＵＤシート片を二次元方向に並べて熱プレスにより一体化することでシート状にしたＣＦＲＰシートも開発されている(例えば、特許文献１参照)。 Therefore, conventionally, a UD sheet in which carbon fiber bundles arranged and aligned in the length direction are bonded and integrated with a matrix resin is finely cut into strips, and the cut strip-shaped UD sheet pieces are arranged in a two-dimensional direction. A CFRP sheet formed into a sheet by being integrated by a hot press has also been developed (for example, see Patent Document 1).
　しかしながら、上記従来のＣＦＲＰシートは、表面に短冊状(矩形状)のＵＤシート片が並んだだけの外観であり、一つ一つのＵＤシート片の形状に大きな違いがなかったため、表面の外観が単調なデザインになり易かった。そのため、意匠性が求められる化粧シート等の用途でＣＦＲＰシートが使用されることは殆どなかった。 However, the above-described conventional CFRP sheet has an appearance in which strip-shaped (rectangular) UD sheet pieces are merely arranged on the surface, and there is no significant difference in the shape of each UD sheet piece. It was easy to be a monotonous design. For this reason, CFRP sheets have rarely been used for applications such as decorative sheets that require design properties.
特開２０１６－２７９５６号公報JP 2016-27956 A
　本発明は、上記問題に鑑みて為されたものであり、その目的とするところは、引張り強度等の機械的強度に優れるだけでなく可視面の意匠性にも優れたＣＦＲＰシート、及びそれを用いた積層体、及び前記ＣＦＲＰシートの効率的な製造方法を提供することにある。 The present invention has been made in view of the above-described problems, and a purpose thereof is to provide a CFRP sheet having not only excellent mechanical strength such as tensile strength but also excellent design of a visible surface, and An object of the present invention is to provide a laminated body used and a method for efficiently producing the CFRP sheet.
　本発明者が上記課題を解決するために採用した手段を添付図面を参照して説明すれば次のとおりである。 The means adopted by the present inventor to solve the above problems will be described below with reference to the accompanying drawings.
　即ち、本発明は、ＣＦＲＰ層Ｓの表面層の外側に透明樹脂層Ｃを形成してＣＦＲＰシートを構成すると共に、前記ＣＦＲＰ層Ｓを、連続繊維状の炭素繊維Ｆ・Ｆ…を長さ方向に揃えて配列した状態でマトリックス樹脂Ｍにより接着一体化して成る多数のＵＤシート片を、各シート片の繊維方向をランダムに配向させた状態で、かつ、各シート片同士が重なり合うように二次元方向に並べた状態でマトリックス樹脂Ｍにより接着して形成する一方、前記ＣＦＲＰ層Ｓの裏面層または中間層のＵＤシート片Ｐ・Ｑ…が矩形状であるのに対し、表面層のＵＤシート片Ｐ・Ｐ…を、裏面層または中間層のＵＤシート片Ｑよりも平均厚みを小さく、かつ、少なくとも一部に非矩形状に歪んだシート片を含んで構成した点に特徴がある。 That is, in the present invention, a CFRP sheet is formed by forming a transparent resin layer C outside the surface layer of the CFRP layer S, and the CFRP layer S is formed by forming continuous fibrous carbon fibers FF in the longitudinal direction. A large number of UD sheet pieces that are bonded and integrated with a matrix resin M in a state where they are aligned in a two-dimensional manner so that the fiber direction of each sheet piece is randomly oriented, and that each sheet piece overlaps each other. While the UD sheet pieces P and Q of the back layer or the intermediate layer of the CFRP layer S are rectangular while the UD sheet pieces of the front layer are rectangular, Each of PP is characterized in that the average thickness is smaller than that of the UD sheet piece Q of the back surface layer or the intermediate layer, and that at least a part includes a non-rectangularly distorted sheet piece.
　なお本明細書中において、「非矩形状」とはＵＤシート片の幅寸法(炭素繊維の長さ方向に対して垂直方向の寸法)の最大値と最小値の差が幅寸法の最大値の10％以上の大きさとなっているもの、またはＵＤシート片の長さ寸法(炭素繊維の長さ方向に対して平行方向の寸法)の最大値と最小値の差が長さ寸法の最大値の10％以上の大きさとなっているものを指す。 In the present specification, the “non-rectangular shape” refers to the difference between the maximum value and the minimum value of the width dimension (dimension in the direction perpendicular to the length direction of the carbon fiber) of the UD sheet piece is the maximum value of the width dimension. The difference between the maximum value and the minimum value of the length dimension of the UD sheet piece (dimension in the direction parallel to the longitudinal direction of the carbon fiber) that is 10% or more, or the difference of the maximum value of the length dimension It refers to the size of 10% or more.
　また本発明は、ＣＦＲＰ層Ｓの表面層の外側に透明樹脂層Ｃが形成されて成るＣＦＲＰシートにおいて、前記ＣＦＲＰ層Ｓが、連続繊維状の炭素繊維Ｆ・Ｆ…を長さ方向に揃えて配列した状態でマトリックス樹脂Ｍにより接着一体化して成る多数のＵＤシート片を、各シート片の繊維方向をランダムに配向させた状態で、かつ、各シート片同士が重なり合うように二次元方向に並べた状態でマトリックス樹脂Ｍにより接着して形成する一方、前記ＣＦＲＰ層Ｓの表面層及び裏面層のＵＤシート片Ｐ・Ｑに非矩形状に歪んだシート片が含まれるように構成することもできる。 Further, the present invention provides a CFRP sheet in which a transparent resin layer C is formed outside a surface layer of the CFRP layer S, wherein the CFRP layer S aligns continuous fibrous carbon fibers FF in a length direction. A large number of UD sheet pieces, which are bonded and integrated with the matrix resin M in an arranged state, are arranged in a two-dimensional direction so that the fiber directions of the respective sheet pieces are randomly oriented, and the respective sheet pieces overlap each other. In this state, the UD sheet pieces P and Q of the surface layer and the back surface layer of the CFRP layer S may include non-rectangularly distorted sheet pieces while being bonded by the matrix resin M in the folded state. .
　また本発明においては、上記ＣＦＲＰ層Ｓの表面層における非矩形状に歪んだＵＤシート片Ｐの割合が30％以上(好ましくは50％以上)とすることで独特の外観の意匠性に優れたＣＦＲＰシートを形成することができる。 Further, in the present invention, the ratio of the non-rectangularly distorted UD sheet piece P in the surface layer of the CFRP layer S is 30% or more (preferably 50% or more), and the unique appearance is excellent in design. A CFRP sheet can be formed.
　一方、本発明においては、上記ＣＦＲＰ層Ｓの表面層におけるＵＤシート片Ｐの一つ当たりの平均面積を、裏面層または中間層のＵＤシート片Ｑの平均面積よりも大きくすることで表面層のＵＤシート片Ｐの形状の歪みを大きくして意匠効果を高めることができる。 On the other hand, in the present invention, the average area per one UD sheet piece P in the surface layer of the CFRP layer S is made larger than the average area of the UD sheet piece Q of the back layer or the intermediate layer to thereby reduce the surface layer. The distortion of the shape of the UD sheet piece P can be increased to enhance the design effect.
　また本発明では、上記ＣＦＲＰ層Ｓの表面層のＵＤシート片Ｐにおける並列する炭素繊維同士が部分的に分離した解け部Ｌの割合を、裏面層または中間層のＵＤシート片Ｑよりも大きくすることで、表面層のＵＤシート片Ｐの形状の歪みを大きくして意匠効果を高めることができる。 In the present invention, the ratio of the unraveled portion L in which the parallel carbon fibers are partially separated from each other in the UD sheet piece P of the surface layer of the CFRP layer S is made larger than that of the UD sheet piece Q of the back layer or the intermediate layer. Thereby, the distortion of the shape of the UD sheet piece P of the surface layer can be increased to enhance the design effect.
　また本発明では、上記ＣＦＲＰ層Ｓのマトリックス樹脂に、透明樹脂層Ｃの熱可塑性樹脂と密着性を有する熱可塑性樹脂を使用することで、透明樹脂層Ｃの形成時に表面層のＵＤシート片Ｐを解け易くすることができる。 Further, in the present invention, by using a thermoplastic resin having adhesiveness to the thermoplastic resin of the transparent resin layer C as the matrix resin of the CFRP layer S, the UD sheet piece P of the surface layer can be formed when the transparent resin layer C is formed. Can be easily unraveled.
　また本発明では、上記ＣＦＲＰシートを同種材料または異種材料の表面に積層一体化することにより独特の外観の意匠性に優れた積層体を構成できる。 In the present invention, a laminate having a unique appearance and excellent design can be formed by laminating and integrating the above CFRP sheet on the surface of the same material or a different material.
　また本発明では、上記ＣＦＲＰシートの製造方法として、二次元方向に並べた多数のＵＤシート片と透明樹脂層の材料である樹脂フィルムとをロール成形して仮接着することにより、或いは二次元方向に並べた多数のＵＤシート片に透明樹脂層の材料である溶融樹脂をコーティングして熱プレスすることによりＣＦＲＰ層と透明樹脂層が一体となった中間シート材を作製した後、この中間シート材を更に熱プレスすることにより表面層のＵＤシート片を歪ませる方法を採用することができる。 Further, in the present invention, as a method for producing the CFRP sheet, a large number of UD sheet pieces arranged in a two-dimensional direction and a resin film as a material of a transparent resin layer are roll-formed and temporarily bonded, or two-dimensionally. The intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated by coating the molten resin as a material of the transparent resin layer on a large number of UD sheet pieces arranged in May be further hot pressed to deform the UD sheet piece of the surface layer.
　また上記製造方法においては、中間シート材に対する熱プレスの加圧力を、ＵＤシート片と樹脂フィルムを仮接着する際のロール成形の加圧力、或いは溶融樹脂がコーティングされたＵＤシート片に対する熱プレスの加圧力よりも大きくするのが好ましい。 In the above manufacturing method, the pressing force of the hot press on the intermediate sheet material, the pressing force of the roll forming when the UD sheet piece and the resin film are temporarily bonded, or the hot pressing of the UD sheet piece coated with the molten resin are used. It is preferable that the pressure is larger than the pressing force.
　一方、本発明では、上記製造方法の代わりに、ＣＦＲＰシートの製造方法において、連続繊維状の炭素繊維と熱可塑性樹脂とをロール成形することにより炭素繊維同士を接着してＵＤシートを作製すると共に、このＵＤシートを矩形状に裁断して作製されたＵＤシート片を透明樹脂層の材料である樹脂フィルム上に二次元方向に配置して、或いは二次元方向に並べた多数のＵＤシート片に透明樹脂層の材料である溶融樹脂をコーティングして加熱圧縮成形することにより表面層のＵＤシート片を歪ませる方法を採用することもできる。 On the other hand, in the present invention, in place of the above-described production method, in a method for producing a CFRP sheet, a continuous fiber carbon fiber and a thermoplastic resin are roll-formed to form a UD sheet by bonding carbon fibers to each other. The UD sheet pieces produced by cutting this UD sheet into a rectangular shape are arranged in a two-dimensional direction on a resin film as a material of a transparent resin layer, or formed into a large number of UD sheet pieces arranged in a two-dimensional direction. It is also possible to adopt a method in which the UD sheet piece of the surface layer is distorted by coating the molten resin which is the material of the transparent resin layer and performing heat compression molding.
　また上記製造方法においては、樹脂フィルムとＵＤシート片に対する加熱圧縮成形の加圧力、或いは溶融樹脂がコーティングされたＵＤシート片に対する加熱圧縮成形の加圧力を、ＵＤシート作製時のロール成形の加圧力よりも大きくするのが好ましい。 Further, in the above manufacturing method, the pressing force of the heat compression molding on the resin film and the UD sheet piece or the pressing force of the heat compression molding on the UD sheet piece coated with the molten resin is determined by the pressing force of the roll forming during the production of the UD sheet. Preferably, it is larger.
　また本発明では、上記製造方法において、表面の意匠性を高めるために樹脂フィルムの目付量を、ＵＤシート片全体の目付量に対して5％以上の大きさとするのが好ましい。 In the present invention, in the above-mentioned production method, it is preferable that the basis weight of the resin film is 5% or more of the basis weight of the entire UD sheet piece in order to enhance the design of the surface.
　本発明では、多数のＵＤシート片を、各シート片の繊維方向をランダムに配向させた状態で、かつ、各シート片同士が重なり合うように二次元方向に並べた状態で接着してＣＦＲＰシートを作製すると共に、表面層に非矩形状に歪んだＵＤシート片を含んで構成したことにより、シート表面に独特の外観を付与することができる。 In the present invention, a large number of UD sheet pieces are bonded in a state in which the fiber direction of each sheet piece is randomly oriented, and in a state where the sheet pieces are arranged in a two-dimensional direction so that the sheet pieces overlap each other, and the CFRP sheet is bonded. A unique appearance can be imparted to the sheet surface by forming and including a non-rectangularly distorted UD sheet piece in the surface layer.
　また本発明では、上記ＣＦＲＰシートの裏面層や中間層を、表面層のＵＤシート片よりも厚みが大きく、かつ、形状が均一な矩形状のＵＤシート片から構成しているため、ＣＦＲＰシートの引張り強度等が大きく損なわれる心配はなく、意匠性と機械的強度を両立することができる。 Further, in the present invention, since the back layer or the intermediate layer of the CFRP sheet is formed of a rectangular UD sheet piece having a thickness greater than that of the UD sheet piece of the surface layer and having a uniform shape, There is no concern that the tensile strength or the like is greatly impaired, and both design properties and mechanical strength can be achieved.
　したがって、本発明により、補強シート等としても問題なく使用することができ、しかも、意匠性が求められる表面シート等としても好適に使用できるＣＦＲＰシートを提供できることから、本発明の実用的利用価値は頗る高い。 Therefore, according to the present invention, a CFRP sheet that can be used as a reinforcing sheet or the like without any problem and can be suitably used as a surface sheet or the like requiring a design property can be provided. Very expensive.
本発明の第一実施形態のＣＦＲＰシートの積層構造を表す概略断面図である。It is a schematic sectional view showing the lamination structure of the CFRP sheet of a first embodiment of the present invention. 本発明の第一実施形態のＣＦＲＰ層の構造を表す概略断面図及び概略平面図である。It is the schematic sectional drawing and schematic plan view showing the structure of the CFRP layer of the first embodiment of the present invention. 本発明の第一実施形態の表面層のＵＤシート片と、裏面層または中間層のＵＤシート片を表す概略図である。It is a schematic diagram showing a UD sheet piece of a surface layer and a UD sheet piece of a back layer or an intermediate layer of a first embodiment of the present invention. 本発明の第二実施形態のＣＦＲＰ層の構造を表す概略断面図及び概略平面図である。It is the schematic sectional drawing and schematic plan view showing the structure of the CFRP layer of 2nd embodiment of this invention. 本発明の効果の実証試験における実施例の外観を表した写真である。It is a photograph showing the appearance of the example in the verification test of the effect of the present invention. 本発明の効果の実証試験における比較例の外観を表した写真である。4 is a photograph showing the appearance of a comparative example in a verification test of the effect of the present invention.
　『第一実施形態』
　本発明の第一実施形態について図１～図３に基づいて以下に説明する。なお図中、符号Ｓで指示するのものは、シート本体であり、符号Ｍで指示するものは、マトリックス樹脂である。また符号Ｐで指示するものは、表面層のＵＤシート片であり、符号Ｑで指示するものは、内側層のＵＤシート片である。また符号Ｆで指示するものは、炭素繊維である。 "First embodiment"
A first embodiment of the present invention will be described below with reference to FIGS. In the drawing, what is indicated by reference numeral S is the sheet body, and what is indicated by reference numeral M is the matrix resin. What is indicated by reference numeral P is a UD sheet piece of the surface layer, and what is indicated by reference sign Q is a UD sheet piece of the inner layer. What is indicated by the symbol F is carbon fiber.
　「ＣＦＲＰシートの構成」
　[１]ＣＦＲＰシートの基本構成について
　まず本実施形態では、図１に示すように、ＣＦＲＰ層Ｓとその可視面側となる表面層の外側に透明樹脂層Ｃを形成してシート本体を構成している。またＣＦＲＰ層Ｓは、図２(a)(b)(c)に示すように、多数のＵＤシート片Ｐ・Ｑをシート片同士が重なり合うように二次元方向に並べ、更にＵＤシート片Ｐ・Ｑの繊維方向をランダムに配向させた(ＵＤシート片の繊維方向の向きがバラバラになるように並べた)炭素繊維材料を、マトリックス樹脂Ｍにより接着一体化して形成している。 "Configuration of CFRP sheet"
[1] Basic Configuration of CFRP Sheet First, in the present embodiment, as shown in FIG. 1, a CFRP layer S and a transparent resin layer C are formed outside a visible surface side surface layer to form a sheet body. ing. Further, as shown in FIGS. 2A, 2B, and 2C, the CFRP layer S has a large number of UD sheet pieces P and Q arranged in a two-dimensional direction such that the sheet pieces overlap each other. Carbon fiber materials in which the fiber directions of Q are randomly oriented (arranged so that the fiber directions of the UD sheet pieces are scattered) are formed by bonding and integrating with a matrix resin M.
　また上記ＣＦＲＰ層ＳのＵＤシート片Ｐ・Ｑには、図３(a)(b)に示すように連続繊維状の炭素繊維Ｆ・Ｆ…を長さ方向に揃えて配列した状態でマトリックス樹脂Ｍにより接着一体化したものを使用している。またＣＦＲＰ層Ｓの非可視面となる裏面層または中間層については、図３(b)に示す矩形状のＵＤシート片Ｑ・Ｑ…を並べて構成する一方、ＣＦＲＰ層Ｓの表面層については、図３(a)に示す裏面層または中間層のＵＤシート片Ｑよりも平均厚みが小さいＵＤシート片Ｐ・Ｐ…を並べて構成し、少なくともその一部に非矩形状に歪んだシート片が含まれるようにしている。 The UD sheet pieces P and Q of the CFRP layer S are arranged in a matrix resin in a state where continuous fibrous carbon fibers FF are aligned in the length direction as shown in FIGS. The one integrated with M is used. The rear layer or the intermediate layer, which is the invisible surface of the CFRP layer S, is configured by arranging rectangular UD sheet pieces Q, Q,... Shown in FIG. 3B, while the surface layer of the CFRP layer S is The UD sheet pieces PP having an average thickness smaller than the UD sheet piece Q of the back layer or the intermediate layer shown in FIG. 3A are arranged side by side, and at least a part thereof includes a non-rectangularly distorted sheet piece. I am trying to be.
　上記のようにシート本体を構成することにより、裏面層や中間層の比較的厚みの大きいＵＤシート片Ｑ・Ｑ…によってＣＦＲＰ層Ｓの機械的強度を確保しつつ、比較的厚みが小さく形状が不均一な表面層のＵＤシート片Ｐ・Ｐ…によって、図２(b)に示すようにシート本体に独特の外観を付与することができる。またＣＦＲＰ層Ｓの表面層の外側に形成した透明樹脂層Ｃによってシート本体の表面の平滑性を向上させることもでき、またＣＦＲＰ層Ｓの保護効果や光学的な視覚効果を付与することもできる。 By configuring the sheet body as described above, the UD sheet pieces Q having relatively large thicknesses of the back layer and the intermediate layer ensure the mechanical strength of the CFRP layer S while having a relatively small thickness and a small shape. By the UD sheet pieces PP having an uneven surface layer, a unique appearance can be given to the sheet body as shown in FIG. 2 (b). The smoothness of the surface of the sheet body can be improved by the transparent resin layer C formed outside the surface layer of the CFRP layer S, and the protective effect and the optical visual effect of the CFRP layer S can be imparted. .
　[２]ＣＦＲＰ層の炭素繊維材料について
　次に上記シート本体の各構成要素について説明する。まず上記ＣＦＲＰ層ＳのＵＤシート片Ｐ・Ｑを構成する連続繊維状の炭素繊維Ｆに関しては、本実施形態ではフィラメントをストランド状に束ねた炭素繊維束(トウ)を使用している。また本実施形態では、炭素繊維ＦにＰＡＮ系炭素繊維を使用しているが、ピッチ系炭素繊維を使用することもできる。なお炭素繊維束を構成するフィラメントの本数は強度等に応じて任意に変更できる。 [2] Regarding carbon fiber material of CFRP layer Next, each component of the above-mentioned sheet body will be described. First, regarding the continuous fibrous carbon fibers F constituting the UD sheet pieces P and Q of the CFRP layer S, in the present embodiment, a carbon fiber bundle (tow) in which filaments are bundled in a strand shape is used. In this embodiment, PAN-based carbon fibers are used as the carbon fibers F, but pitch-based carbon fibers can be used. The number of filaments constituting the carbon fiber bundle can be arbitrarily changed according to the strength and the like.
　[３]ＣＦＲＰ層のマトリックス樹脂について
　また上記ＣＦＲＰ層Ｓのマトリックス樹脂Ｍに関しては、本実施形態ではポリアミド系樹脂(ナイロン樹脂)を使用しているが、これに限らず炭素繊維材料に対して含浸性を有する他の熱可塑性樹脂(アクリル樹脂やポリエステル、ポリオレフィン、ポリスチレン、ポリカーボネート、ＡＢＳ樹脂、ポリエーテルイミド、フッ素系樹脂、ポリフェニレンサルファイド等)や、熱硬化性樹脂を使用することもできる。 [3] Regarding the matrix resin of the CFRP layer The polyamide resin (nylon resin) is used in the present embodiment for the matrix resin M of the CFRP layer S, but the present invention is not limited to this, and the carbon fiber material is impregnated. Other thermoplastic resins having properties (acrylic resin, polyester, polyolefin, polystyrene, polycarbonate, ABS resin, polyetherimide, fluororesin, polyphenylene sulfide, etc.) and thermosetting resins can also be used.
　またＣＦＲＰ層Ｓと透明樹脂層Ｃを熱プレスにより一体化する場合(詳しくは後述する)には、ＣＦＲＰ層Ｓのマトリックス樹脂に、透明樹脂層Ｃの熱可塑性樹脂と密着性を有する熱可塑性樹脂を使用することで、熱プレス時に表面層のＵＤシート片Ｐを解け易くすることができる。 In the case where the CFRP layer S and the transparent resin layer C are integrated by hot pressing (details will be described later), a thermoplastic resin having adhesiveness to the thermoplastic resin of the transparent resin layer C is added to the matrix resin of the CFRP layer S. Is used, the UD sheet piece P of the surface layer can be easily unraveled during hot pressing.
　[４]ＵＤシート片の形状について
　[4-1]表面層のＵＤシート片の形状
　また上記ＣＦＲＰ層Ｓの表面層のＵＤシート片Ｐに関しては、本実施形態では意匠効果を高めるために非矩形状に歪んだＵＤシート片Ｐの割合を30％以上にしている。なお非矩形状のＵＤシート片Ｐについては、図３(a)に示すようにＵＤシート片の長さ寸法の最大値Ｘ1と最小値Ｘ2の差が最大値Ｘ1の10％以上の大きさとなるもの、または幅寸法の最大値Ｙ1と最小値Ｙ2の差が最大値Ｙ1の10％以上となるものを指す。 [4] Shape of UD sheet piece [4-1] Shape of UD sheet piece of surface layer Regarding the UD sheet piece P of the surface layer of the CFRP layer S, in this embodiment, a non-rectangular shape is used in order to enhance the design effect. The ratio of the UD sheet piece P distorted in shape is set to 30% or more. With respect to the aspherical rectangular UD sheet piece P, FIGS. 3 (a) are shown as UD sheet piece difference between the maximum value X 1 and the minimum value X 2 of the linear dimension of more than 10% of the maximum value X 1 of that the size, or refers to what the difference between the maximum value Y 1 and the minimum value Y 2 of the width is equal to or more than 10% of the maximum value Y 1.
　また上記表面層のＵＤシート片Ｐの厚みに関しては、本実施形態では表面層のＵＤシート片Ｐの形状の歪みが大きくなるように平均厚みが裏面層または中間層のＵＤシート片Ｑの平均厚みの半分程度となるようにしている。また本実施形態では、ＵＤシート片Ｐの幅寸法の最大値Ｙ1の平均値を平均幅として、この平均幅が裏面層または中間層のＵＤシート片Ｑの平均幅の1.5倍以上となるようにしている。また本実施形態では、上記表面層のＵＤシート片Ｐの一つ当たりの平均面積が、内側層のＵＤシート片Ｑの平均面積よりも大きくなるようにしている。 Further, regarding the thickness of the UD sheet piece P of the surface layer, in the present embodiment, the average thickness of the UD sheet piece Q of the back layer or the intermediate layer is set so that the shape of the UD sheet piece P of the surface layer becomes large. About half of that. In the present embodiment, the average value of the maximum value Y 1 of the width of the UD sheet piece P as the average width, so that the average width is equal to or greater than 1.5 times the average width of the UD sheet piece Q of the back layer or the intermediate layer I have to. Further, in the present embodiment, the average area of one UD sheet piece P of the surface layer is larger than the average area of the UD sheet piece Q of the inner layer.
　また本実施形態では、上記表面層のＵＤシート片Ｐの形状の歪みが大きくなるように、表面層のＵＤシート片Ｐの平均幅が、裏面層または中間層のＵＤシート片Ｑの平均幅よりも大きくなるようにしている。また同様の目的で、表面層のＵＤシート片Ｐの並列する炭素繊維Ｆ同士が部分的に分離した解け部Ｌの割合が裏面層または中間層のＵＤシート片Ｑよりも大きくなるようにしている。 In the present embodiment, the average width of the UD sheet piece P of the surface layer is set to be larger than the average width of the UD sheet piece Q of the back layer or the intermediate layer so that the shape of the UD sheet piece P of the surface layer increases. Is also getting bigger. For the same purpose, the ratio of the unraveled portion L in which the parallel carbon fibers F of the UD sheet piece P of the surface layer are partially separated from each other is made larger than that of the UD sheet piece Q of the back layer or the intermediate layer. .
　[4-2]裏面層または中間層のＵＤシート片の形状
　また上記ＣＦＲＰ層Ｓの裏面層または中間層のＵＤシート片Ｑに関しては、本実施形態では幅Ｗ5mm×長さＬ20mmのものを使用しているが、強度や賦形性を考慮して幅Ｗ2mm～20mm(好ましくは5mm～10mm)、長さＬ5mm～70mm(好ましくは10mm～30mm)、幅Ｗと長さＬの比率１：１～１：６の矩形状のものを使用するのが好ましい。なお本明細書中においては、炭素繊維Ｆの長さ方向に沿った方向をＵＤシート片Ｐの長さ方向とし、それに垂直な方向を幅方向とする。また裏面層または中間層のＵＤシート片Ｑの厚みに関しては、40μｍ～100μｍの範囲とするのが好ましい。 [4-2] Shape of UD sheet piece of back layer or intermediate layer Regarding the UD sheet piece Q of the back layer or intermediate layer of the CFRP layer S, the one having a width of W5 mm and a length of L20 mm is used in the present embodiment. However, in consideration of strength and formability, width W 2 mm to 20 mm (preferably 5 mm to 10 mm), length L 5 mm to 70 mm (preferably 10 mm to 30 mm), ratio of width W to length L 1: 1 to 1 It is preferable to use a 1: 6 rectangular shape. In this specification, the direction along the length direction of the carbon fiber F is defined as the length direction of the UD sheet piece P, and the direction perpendicular to the direction is defined as the width direction. Further, the thickness of the UD sheet piece Q of the back layer or the intermediate layer is preferably in the range of 40 μm to 100 μm.
　[4-3]ＵＤシート片の重ね枚数
　また本実施形態では、上記ＣＦＲＰ層Ｓ中に積層するＵＤシート片Ｐ・Ｑの厚さ方向の平均枚数を、5.0枚～8.0枚の範囲に設計しているが、シート本体の強度に応じて任意の枚数で設計することができる。またＣＦＲＰ層Ｓの厚みに関しては、0.3mm～1.0mmの範囲で設計するのが好ましいが、これよりも厚い板状に形成することもできる。 [4-3] Number of stacked UD sheet pieces In the present embodiment, the average number of UD sheet pieces P and Q stacked in the CFRP layer S in the thickness direction is designed to be in a range of 5.0 to 8.0 sheets. However, any number of sheets can be designed according to the strength of the sheet body. Further, the thickness of the CFRP layer S is preferably designed in the range of 0.3 mm to 1.0 mm, but it can be formed in a thicker plate shape.
　[５]ＣＦＲＰ層の表面層・裏面層・中間層について
　また上記ＣＦＲＰ層Ｓの可視面となる表面層については、本実施形態ではシート本体の片面のみに形成しているが、シート本体の両面に形成することもできる。その場合、ＣＦＲＰ層Ｓの裏面層は存在せず表面層と中間層のみで構成される。またＣＦＲＰ層Ｓの厚みが非常に小さい場合には、中間層が存在せず表面層と裏面層のみで構成されるケースもあり得る。 [5] Surface Layer / Back Layer / Intermediate Layer of CFRP Layer The surface layer serving as the visible surface of the CFRP layer S is formed on only one surface of the sheet body in the present embodiment, but is formed on both surfaces of the sheet body. Can also be formed. In that case, the CFRP layer S does not have a back surface layer, and is composed of only a surface layer and an intermediate layer. When the thickness of the CFRP layer S is very small, there may be a case where the intermediate layer does not exist and is composed of only the front surface layer and the back surface layer.
　[６]透明樹脂層について
　[6-1]透明樹脂層の材料
　また上記透明樹脂層Ｃの材料については、本実施形態ではポリアミド系樹脂を使用しているが、これに限らず炭素繊維材料に対して含浸性を有する他の熱可塑性樹脂(アクリル樹脂やＰＥＴ、ポリエチレン、ポリスチレン、ポリカーボネート、ＡＢＳ樹脂、ポリエーテルイミド、フッ素系樹脂、ポリフェニレンサルファイド等)や、熱硬化性樹脂を使用することもできる。また透明樹脂層Ｃは、無色透明なものだけでなく若干色が付いた半透明のものも含まれる。 [6] Regarding Transparent Resin Layer [6-1] Material of Transparent Resin Layer The material of the transparent resin layer C is a polyamide resin in the present embodiment, but is not limited to this. Other thermoplastic resins having an impregnating property (acrylic resin, PET, polyethylene, polystyrene, polycarbonate, ABS resin, polyetherimide, fluororesin, polyphenylene sulfide, etc.) and thermosetting resins can also be used. . The transparent resin layer C includes not only a colorless and transparent layer but also a slightly colored translucent layer.
　[6-2]透明樹脂層の厚み
　また透明樹脂層Ｃの厚みについては、ＣＦＲＰ層Ｓの厚みが小さい場合、材料として使用する樹脂フィルムの目付量を、ＵＤシート片全体の目付量に対して5％以上(より好ましくは5～100％、更に好ましくは10～50％)の大きさとするのが好ましい。なおＣＦＲＰ層Ｓの厚みが大きい場合(分厚い板状に形成する場合)には、樹脂フィルムの目付量をＵＤシート片全体の目付量に対して5％よりも小さくすることもできる。 [6-2] Thickness of Transparent Resin Layer Regarding the thickness of the transparent resin layer C, when the thickness of the CFRP layer S is small, the basis weight of the resin film used as a material is determined with respect to the basis weight of the entire UD sheet piece. The size is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%). When the thickness of the CFRP layer S is large (when the CFRP layer S is formed in a thick plate shape), the weight per unit area of the resin film may be smaller than 5% of the total weight of the UD sheet piece.
　「ＣＦＲＰシートの製造方法(i)」
　次に上記ＣＦＲＰシートの製造方法(i)について説明する。本製法においては、まずＵＤシートを裁断して均一な矩形状のＵＤシート片を作製した後、二次元方向に並べた多数のＵＤシート片と透明樹脂層の材料である熱可塑性樹脂フィルムとをロール成形することにより両者を仮接着して、ＣＦＲＰ層と透明樹脂層が一体となった中間シート材を作製する。そしてロール成形により作製された中間シート材を、更に熱プレスして表面層のＵＤシート片を歪ませた後、冷却プレスを行う。 "Production method of CFRP sheet (i)"
Next, the method (i) for producing the CFRP sheet will be described. In this production method, first, a UD sheet is cut to form a uniform rectangular UD sheet piece, and then a large number of UD sheet pieces arranged in a two-dimensional direction and a thermoplastic resin film that is a material of a transparent resin layer. The two are temporarily bonded by roll forming to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated. Then, the intermediate sheet material produced by roll forming is further hot-pressed to deform the UD sheet piece of the surface layer, and then subjected to a cooling press.
　なお上記表面層のＵＤシート片が歪む原理については、ＣＦＲＰ層表面の微細な凹凸に溶融した透明樹脂が流動(変形)して入り込む際に、加熱により結合力が弱まったＵＤシート片の炭素繊維がつられて移動することで生じるものと推測される。また上記熱プレス時に炭素繊維同士の結合力が弱まったＵＤシート片が潰されて炭素繊維が幅方向に移動することで、表面層のＵＤシート片の厚みが裏面層または中間層のＵＤシート片の厚みよりも小さくなり、かつ、表面層のＵＤシート片の幅寸法が裏面層または中間層のＵＤシート片の幅寸法よりも大きくなる。 Note that the principle that the UD sheet piece of the surface layer is distorted is that, when the transparent resin melted into the fine irregularities on the surface of the CFRP layer flows (deforms) and enters, the carbon fiber of the UD sheet piece whose bonding force is weakened by heating. It is presumed to be caused by the movement of Further, the UD sheet pieces having weakened bonding force between the carbon fibers at the time of the hot pressing are crushed and the carbon fibers move in the width direction, so that the thickness of the UD sheet pieces of the surface layer becomes smaller than that of the back layer or the intermediate layer. And the width dimension of the UD sheet piece of the front surface layer is larger than the width dimension of the UD sheet piece of the back layer or the intermediate layer.
　また本製法では、上記中間シート材に対する熱プレスの加圧力を、ＵＤシート片と樹脂フィルムを仮接着する際のロール成形の加圧力よりも大きくすることにより、透明樹脂の流動性(変形性)を高めて表面層のＵＤシート片の形状を大きく歪曲させている。また中間シート材に対する熱プレスの加圧力を高めることで、表面層のＵＤシート片により多くの解け部を形成することができる。 In addition, in this manufacturing method, the pressing force of the hot press on the intermediate sheet material is made larger than the pressing force of the roll forming when the UD sheet piece and the resin film are temporarily bonded, so that the fluidity (deformability) of the transparent resin is increased. And the shape of the UD sheet piece of the surface layer is greatly distorted. Further, by increasing the pressing force of the hot press on the intermediate sheet material, it is possible to form more unraveled portions on the UD sheet piece of the surface layer.
　また本製法においては、上記のように透明樹脂層の材料に熱可塑性樹脂フィルムを使用しているが、樹脂フィルムの代わりに粒状または短繊維状の熱可塑性樹脂を積層してＵＤシート片に仮接着し、これらを熱プレスして透明樹脂層を形成することもでき、その場合にも上記と同様、表面層のＵＤシート片を歪ませることができる。また上記樹脂フィルムの目付量は、ＵＤシート片全体の目付量に対して5％以上(より好ましくは5～100％、更に好ましくは10～50％)の大きさとするのが好ましい。 Further, in the present production method, a thermoplastic resin film is used as the material of the transparent resin layer as described above. However, instead of the resin film, a granular or short fiber thermoplastic resin is laminated and temporarily formed on a UD sheet piece. The transparent resin layer can also be formed by bonding and hot pressing them. In this case, the UD sheet piece of the surface layer can be distorted in the same manner as described above. The basis weight of the resin film is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%) with respect to the basis weight of the entire UD sheet piece.
　また上記中間シート材の作製方法については、必ずしも樹脂フィルムを使用する必要はなく、二次元方向に並べた多数のＵＤシート片に対し、透明樹脂層の材料である溶融樹脂をコーティングして熱プレスすることによりＣＦＲＰ層と透明樹脂層が一体となった中間シート材を作製することもできる。またその場合には、中間シート材に対する熱プレスの加圧力を、溶融樹脂がコーティングされたＵＤシート片に対する熱プレスの加圧力よりも大きくするのが好ましい。 Regarding the method of producing the intermediate sheet material, it is not always necessary to use a resin film, and a large number of UD sheet pieces arranged in a two-dimensional direction are coated with a molten resin as a material of a transparent resin layer and hot pressed. By doing so, it is possible to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated. In this case, it is preferable that the pressing force of the hot press on the intermediate sheet material is larger than the pressing force of the hot press on the UD sheet piece coated with the molten resin.
　「ＣＦＲＰシートの製造方法(ii)」
　次に上記ＣＦＲＰシートの製造方法(ii)について説明する。本製法においては、連続繊維状の炭素繊維と熱可塑性樹脂とをロール成形することにより炭素繊維同士を接着してＵＤシートを作製すると共に、このＵＤシートを裁断して均一な矩形状のＵＤシート片を作製する。その後、透明樹脂層の材料である熱可塑性樹脂フィルム上にＵＤシート片を二次元方向に並べて配置し、これらを加熱圧縮成形(スタンパブル成形等)することにより表面層のＵＤシート片を歪ませてシート本体を製造する。 "Production method of CFRP sheet (ii)"
Next, the method (ii) for producing the CFRP sheet will be described. In this production method, a continuous fibrous carbon fiber and a thermoplastic resin are roll-formed to bond the carbon fibers together to form a UD sheet, and the UD sheet is cut to form a uniform rectangular UD sheet. Make a piece. After that, the UD sheet pieces are arranged in a two-dimensional direction on a thermoplastic resin film which is a material of the transparent resin layer, and the UD sheet pieces of the surface layer are distorted by heating and compression molding (such as stampable molding). Manufacture the seat body.
　また本製法では、上記樹脂フィルムとＵＤシート片に対する加熱圧縮成形の加圧力を、ＵＤシート作製時のロール成形の加圧力よりも大きくすることにより、透明樹脂の流動性(変形性)を高めて表面層のＵＤシート片の形状を大きく歪曲させている。また樹脂フィルムとＵＤシート片に対する加熱圧縮成形の加圧力を高めることで、表面層のＵＤシート片により多くの解け部を形成することができる。 In addition, in the present production method, the flowability (deformability) of the transparent resin is increased by setting the pressure of the heat compression molding on the resin film and the UD sheet piece larger than the pressure of the roll molding at the time of producing the UD sheet. The shape of the UD sheet piece of the surface layer is greatly distorted. In addition, by increasing the pressing force of the heat compression molding on the resin film and the UD sheet piece, it is possible to form more melting portions in the UD sheet piece of the surface layer.
　また本製法においては、上記熱可塑性樹脂フィルムの代わりに粒状または短繊維状の熱可塑性樹脂を積層して透明樹脂層を形成することもでき、その場合にも上記と同様、表面層のＵＤシート片を歪ませることができる。また上記樹脂フィルムの目付量は、ＵＤシート片全体の目付量に対して5％以上(より好ましくは5～100％、更に好ましくは10～50％)の大きさとするのが好ましい。 In the present production method, a granular or short-fiber thermoplastic resin may be laminated instead of the thermoplastic resin film to form a transparent resin layer. In this case, the UD sheet of the surface layer may be formed as described above. The pieces can be distorted. The basis weight of the resin film is preferably 5% or more (more preferably 5 to 100%, further preferably 10 to 50%) with respect to the basis weight of the entire UD sheet piece.
　また上記加熱圧縮成形に関しては、必ずしも樹脂フィルムを使用する必要はなく、層状に並べた多数のＵＤシート片に透明樹脂層の材料である溶融樹脂をコーティングしたものに対して行うこともできる。 The heat compression molding does not necessarily require the use of a resin film, but may be performed on a multiplicity of layered UD sheet pieces coated with a molten resin as a material of a transparent resin layer.
　『第二実施形態』
　[１]ＣＦＲＰシートの基本構成について
　まず本実施形態では、図４(a)(b)(c)に示すように、ＵＤシート片Ｐ・Ｑの重ね枚数を減らしてＣＦＲＰ層Ｓを薄く形成すると共に、ＣＦＲＰ層Ｓの表面層及び裏面層のＵＤシート片Ｐ・Ｑ…の両方に非矩形状に歪んだシート片が含まれるように構成している。また本実施形態では、上記ＣＦＲＰ層Ｓの表面層におけるＵＤシート片Ｐの一つ当たりの平均面積が、裏面層のＵＤシート片Ｑの平均面積よりも大きくなるようにしている。 "Second embodiment"
[1] Basic Configuration of CFRP Sheet First, in the present embodiment, as shown in FIGS. 4A, 4B, and 4C, the number of overlapping UD sheet pieces P and Q is reduced to form a thin CFRP layer S. In addition, both of the UD sheet pieces P, Q,... Of the front layer and the back layer of the CFRP layer S are configured to include non-rectangularly distorted sheet pieces. In this embodiment, the average area per UD sheet piece P in the surface layer of the CFRP layer S is larger than the average area of the UD sheet piece Q in the back layer.
　また上記ＣＦＲＰ層Ｓについては、透明樹脂が裏面層まで入り込むように厚さ0.1mm～0.2mm(ＵＤシート片Ｐ・Ｑの平均重ね枚数2枚～4枚)の範囲内とするのが好ましい。また上記ＣＦＲＰ層Ｓの表面層のＵＤシート片Ｐは、非矩形状に歪んだＵＤシート片Ｐの割合が30％以上(好ましくは50％以上)とするのが好ましい。 The thickness of the CFRP layer S is preferably in the range of 0.1 mm to 0.2 mm (average number of UD sheet pieces P and Q: 2 to 4) so that the transparent resin enters the back layer. In the UD sheet piece P of the surface layer of the CFRP layer S, the ratio of the UD sheet piece P distorted in a non-rectangular shape is preferably 30% or more (preferably 50% or more).
　上記のようにシート本体を構成することにより、シート本体に独特の外観を付与することができる。またＣＦＲＰ層Ｓの表面層の外側に形成した透明樹脂層Ｃによってシート本体の表面の平滑性を向上させることもでき、またＣＦＲＰ層Ｓの保護効果や光学的な視覚効果を付与できる。なおその他の構成および製造方法については、第一実施形態と同様である。 構成 By configuring the seat body as described above, a unique appearance can be imparted to the seat body. The smoothness of the surface of the sheet body can be improved by the transparent resin layer C formed outside the surface layer of the CFRP layer S, and the protective effect and the optical visual effect of the CFRP layer S can be provided. Other configurations and manufacturing methods are the same as in the first embodiment.
　『第三実施形態』
　「ＣＦＲＰシートを用いた積層体の構成」
　次に本発明の第三実施形態について説明する。本実施形態では、第一実施形態のＣＦＲＰシートをプラスチック材料の表面に熱プレスで積層一体化することにより表面の意匠性に優れた積層体を構成している(図示せず)。またＣＦＲＰシートを積層する対象としては、プラスチック材料だけでなく同種のＣＦＲＰ材料や金属等の異種材料を採用することもできる。 "Third embodiment"
"Configuration of laminate using CFRP sheet"
Next, a third embodiment of the present invention will be described. In this embodiment, the CFRP sheet of the first embodiment is laminated and integrated on the surface of a plastic material by hot pressing to form a laminate having excellent surface design (not shown). In addition, as a target for laminating the CFRP sheets, not only a plastic material but also a different material such as a same kind of CFRP material or metal can be adopted.
　[効果の実証試験(i)]
　次に本発明の効果の実証試験(i)について説明する。本試験では、透明樹脂層の有無および表面層のＵＤシート片の非矩形状の割合および幅寸法が異なるＣＦＲＰシートのサンプルを複数作製し、これら各サンプル(下記の実施例１及び比較例１～２)の外観を評価した。 [Effect verification test (i)]
Next, the verification test (i) of the effect of the present invention will be described. In this test, a plurality of CFRP sheet samples were prepared in which the presence or absence of the transparent resin layer and the non-rectangular ratio and width of the UD sheet pieces of the surface layer were different, and each of these samples (Example 1 and Comparative Examples 1 to 5 below) was prepared. The appearance of 2) was evaluated.
　「実施例１」
　本実施例では、第一実施形態の構成から成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂および透明樹脂層の熱可塑性樹脂にそれぞれポリアミド系樹脂(ナイロン６)を使用し、製造方法(i)の方法によってサンプルの作製を行った。また本実施例では、仮接着時のロール成形の加圧力(中間シート材を製造する際の加圧力)を0.2～0.4MPaとし、中間シート材に対する熱プレスの加圧力(中間シート材からシート本体を製造する際の加圧力)を3MPaとした。 "Example 1"
In this example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer in the CFRP sheet having the configuration of the first embodiment, and the method of the manufacturing method (i) was used. A sample was produced by the method described above. In this embodiment, the pressing force of the roll forming at the time of temporary bonding (the pressing force at the time of manufacturing the intermediate sheet material) is set to 0.2 to 0.4 MPa, and the pressing force of the hot press on the intermediate sheet material (from the intermediate sheet material to the sheet body). Was 3 MPa.
　そして、上記ＣＦＲＰ層の表面層の一部(10cm×10cm=100cm2)を目視確認したところ、表面層における非矩形状のＵＤシート片の割合は100％であり、またＵＤシート片の幅寸法が成形前の状態から1.5倍以上の大きさまで拡大したものの割合も100％であった。その結果、図５に示す外観となり独特の外観を有する意匠性の高いサンプルを作製できた。 Then, when a part (10 cm × 10 cm = 100 cm 2 ) of the surface layer of the CFRP layer was visually checked, the ratio of the non-rectangular UD sheet piece in the surface layer was 100%, and the width of the UD sheet piece was However, the ratio of those which were expanded to a size of 1.5 times or more from the state before molding was also 100%. As a result, a highly designable sample having the appearance shown in FIG. 5 and having a unique appearance was produced.
　「比較例１」
　本実施例では、第一実施形態の構成から成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂および透明樹脂層の熱可塑性樹脂にそれぞれポリアミド系樹脂(ナイロン６)を使用し、実施例１と同様、製造方法(i)の方法によってサンプルの作製を行った。そして、ＣＦＲＰ層の裏面層の一部(10cm×10cm=100cm2)を目視で確認したところ、裏面層における非矩形状のＵＤシート片の割合は24％に留まり、ＵＤシート片の幅寸法が1.5倍以上の大きさまで拡大したものの割合も18％に留まった。その結果、図６(a)に示す外観となりサンプルの意匠効果を充分に高めることができなかった。 "Comparative Example 1"
In the present example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer, respectively, in the CFRP sheet having the configuration of the first embodiment. A sample was prepared by the method (i). Then, when a part (10 cm × 10 cm = 100 cm 2 ) of the back layer of the CFRP layer was visually confirmed, the ratio of the non-rectangular UD sheet pieces in the back layer was only 24%, and the width dimension of the UD sheet pieces was smaller. The ratio of those that expanded to 1.5 times or more was only 18%. As a result, the appearance was as shown in FIG. 6A, and the design effect of the sample could not be sufficiently enhanced.
　「比較例２」
　本実施例では、透明樹脂層を有しないＣＦＲＰ層のみから成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂にポリアミド系樹脂(ナイロン６)を使用し、ＵＤシート片を熱プレス加工してサンプルの作製を行った。そして、ＣＦＲＰ層の表面層の一部(10cm×10cm=100cm2)を目視確認したところ、表面層における非矩形状のＵＤシート片の割合は0％であり、ＵＤシート片の幅寸法が成形前の状態から1.5倍以上の大きさまで拡大したものの割合も0％であった。その結果、図６(b)に示す外観となりサンプルの意匠効果を充分に高めることができなかった。 "Comparative Example 2"
In this example, a CFRP sheet consisting of only a CFRP layer having no transparent resin layer was prepared by using a polyamide resin (nylon 6) as a matrix resin of the CFRP layer and hot pressing a UD sheet piece to prepare a sample. went. Then, when a part (10 cm × 10 cm = 100 cm 2 ) of the surface layer of the CFRP layer was visually confirmed, the proportion of the non-rectangular UD sheet piece in the surface layer was 0%, and the width dimension of the UD sheet piece was formed. The ratio of those that were enlarged to 1.5 times or more from the previous state was also 0%. As a result, the appearance was as shown in FIG. 6B, and the design effect of the sample could not be sufficiently enhanced.
　＜試験結果＞
　上記実施例１及び比較例１～２についての試験結果をまとめると、実施例１のサンプルは意匠性を充分に高めることができたのに対し、比較例１～２のサンプルは意匠性を充分に高めることができなかった。各サンプルの条件と試験結果をまとめた表を以下に示す。
Figure JPOXMLDOC01-appb-T000001
 <Test results>
To summarize the test results of Example 1 and Comparative Examples 1 and 2, the sample of Example 1 was able to sufficiently improve the design, whereas the samples of Comparative Examples 1 and 2 were sufficiently improved in the design. Could not be increased. A table summarizing the conditions and test results of each sample is shown below.
Figure JPOXMLDOC01-appb-T000001
　[効果の実証試験(ii)]
　次に本発明の効果の実証試験(ii)について説明する。本試験では、透明樹脂層の材料及び材料として使用するＵＤシート片の幅寸法、Vf値が異なるＣＦＲＰシートのサンプルを複数作製し、これら各サンプル(下記の実施例１及び比較例１～２)の外観を評価した。 [Effect test (ii)]
Next, the demonstration test (ii) of the effect of the present invention will be described. In this test, a plurality of CFRP sheet samples having different width dimensions and Vf values of the UD sheet piece used as the material of the transparent resin layer and the material were prepared, and these samples (Example 1 and Comparative Examples 1 and 2 described below) were prepared. Was evaluated for appearance.
　「実施例１」
　本実施例では、第二実施形態の構成から成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂および透明樹脂層の熱可塑性樹脂にそれぞれポリアミド系樹脂(ナイロン６)を使用し、製造方法(i)によってサンプルの作製を行った。また本実施例では、材料として寸法が幅5mm×長さ20mm×厚さ0.043mm、Vf53％のＵＤシート片を使用した。 "Example 1"
In this example, a polyamide resin (nylon 6) was used for the matrix resin of the CFRP layer and the thermoplastic resin of the transparent resin layer in the CFRP sheet having the configuration of the second embodiment, and the sample was produced by the production method (i). Was prepared. In this embodiment, a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.043 mm, and a Vf of 53% was used as a material.
　また本実施例では、二次元方向に並べた上記ＵＤシート片と透明樹脂層の材料である熱可塑性樹脂フィルムとをロール温度270℃、ロール加圧力0.5MPaの条件でロール成形し、目付150g/m2、厚み0.15mm、Vf43.3％の中間シート材を作製した。そして、この中間シート材に対して金型温度270℃、加圧力3MPa、加圧時間0.5minの条件下で熱プレスを行った後、金型温度30℃、加圧力5MPa、加圧時間3minの条件下で冷却プレスを行って寸法が幅381mm×長さ277mm×厚さ0.12mm、Vf43.3％のシート本体を作製した。その結果、独特の外観を有する意匠性の高いサンプルを作製できた。 Further, in the present embodiment, the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa. An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 43.3% was produced. Then, after hot pressing was performed on the intermediate sheet material under the conditions of a mold temperature of 270 ° C., a pressing force of 3 MPa and a pressing time of 0.5 min, the mold temperature was 30 ° C., the pressing force was 5 MPa, and the pressing time was 3 min. A cooling press was performed under the conditions to produce a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and Vf of 43.3%. As a result, a highly designable sample having a unique appearance was produced.
　「実施例２」
　本実施例では、第二実施形態の構成から成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂にポリフェニレンサルファイド(PPS)樹脂、透明樹脂層の熱可塑性樹脂にポリアミド系樹脂を使用し、製造方法(i)によってサンプルの作製を行った。また本実施例では、材料として寸法が幅5mm×長さ20mm×厚さ0.048mm、Vf47％のＵＤシート片を使用した。 "Example 2"
In this example, in a CFRP sheet having the configuration of the second embodiment, a polyphenylene sulfide (PPS) resin was used as the matrix resin of the CFRP layer, and a polyamide resin was used as the thermoplastic resin of the transparent resin layer. A sample was produced by the method described above. In this embodiment, a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.048 mm, and a Vf of 47% was used as a material.
　また本実施例では、二次元方向に並べた上記ＵＤシート片と透明樹脂層の材料である熱可塑性樹脂フィルムとをロール温度270℃、ロール加圧力0.5MPaの条件でロール成形し、目付150g/m2、厚み0.15mm、Vf35％の中間シート材を作製した。そして、この中間シート材に対して金型温度320℃、加圧力3MPa、加圧時間0.5minの条件下で熱プレスを行った後、金型温度30℃、加圧力5MPa、加圧時間3minの条件下で冷却プレスを行って寸法が幅381mm×長さ277mm×厚さ0.12mm、Vf35％のシート本体を作製した。その結果、独特の外観を有する意匠性の高いサンプルを作製できた。 Further, in the present embodiment, the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa. An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 35% was produced. Then, after performing a hot press on the intermediate sheet material under the conditions of a mold temperature of 320 ° C., a pressing force of 3 MPa and a pressing time of 0.5 min, the mold temperature is 30 ° C., a pressing force of 5 MPa, and a pressing time of 3 min. A cooling press was performed under the conditions to prepare a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and 35% Vf. As a result, a highly designable sample having a unique appearance was produced.
　「実施例３」
　本実施例では、第二実施形態の構成から成るＣＦＲＰシートにおいて、ＣＦＲＰ層のマトリックス樹脂にポリカーボネート(PC)樹脂、透明樹脂層の熱可塑性樹脂にポリアミド系樹脂を使用し、製造方法(i)によってサンプルの作製を行った。また本実施例では、材料として寸法が幅5mm×長さ20mm×厚さ0.048mm、Vf47％のＵＤシート片を使用した。 "Example 3"
In the present example, in the CFRP sheet having the configuration of the second embodiment, a polycarbonate resin (PC) is used as the matrix resin of the CFRP layer, and a polyamide resin is used as the thermoplastic resin of the transparent resin layer. A sample was prepared. In this embodiment, a UD sheet piece having a width of 5 mm, a length of 20 mm, a thickness of 0.048 mm, and a Vf of 47% was used as a material.
　また本実施例では、二次元方向に並べた上記ＵＤシート片と透明樹脂層の材料である熱可塑性樹脂フィルムとをロール温度270℃、ロール加圧力0.5MPaの条件でロール成形し、目付150g/m2、厚み0.15mm、Vf35％の中間シート材を作製した。そして、この中間シート材に対して金型温度300℃、加圧力3MPa、加圧時間0.5minの条件下で熱プレスを行った後、金型温度30℃、加圧力5MPa、加圧時間3minの条件下で冷却プレスを行って寸法が幅381mm×長さ277mm×厚さ0.12mm、Vf35％のシート本体を作製した。その結果、独特の外観を有する意匠性の高いサンプルを作製できた。 Further, in the present embodiment, the UD sheet pieces arranged in the two-dimensional direction and the thermoplastic resin film as the material of the transparent resin layer were roll-formed under the conditions of a roll temperature of 270 ° C. and a roll pressure of 0.5 MPa. An intermediate sheet material having m2, thickness of 0.15 mm and Vf of 35% was produced. Then, after performing a hot press on the intermediate sheet material under the conditions of a mold temperature of 300 ° C., a pressing force of 3 MPa, and a pressing time of 0.5 min, a mold temperature of 30 ° C., a pressing force of 5 MPa, and a pressing time of 3 min. A cooling press was performed under the conditions to prepare a sheet body having dimensions of 381 mm in width, 277 mm in length, 0.12 mm in thickness, and 35% Vf. As a result, a highly designable sample having a unique appearance was produced.
　＜試験結果＞
　上記実施例２～４についての試験結果をまとめると、実施例１～３の何れのサンプルについても意匠性を充分に高めることができた。なお各サンプルの条件をまとめた表を以下に示す。
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000004
 <Test results>
When the test results of Examples 2 to 4 are summarized, the design of each of the samples of Examples 1 to 3 was sufficiently improved. A table summarizing the conditions of each sample is shown below.
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000004
　Ｓ　ＣＦＲＰ層
　Ｍ　透明樹脂層
　Ｐ　表面層のＵＤシート片
　Ｑ　裏面層または中間層のＵＤシート片 S CFRP layer M Transparent resin layer P UD sheet piece of surface layer Q UD sheet piece of back layer or intermediate layer

Claims (11)

  1. 　ＣＦＲＰ層(Ｓ)の表面層の外側に透明樹脂層(Ｃ)が形成されて成るＣＦＲＰシートにおいて、
    前記ＣＦＲＰ層(Ｓ)が、連続繊維状の炭素繊維(Ｆ)(Ｆ)…を長さ方向に揃えて配列した状態でマトリックス樹脂(Ｍ)により接着一体化して成る多数のＵＤシート片を、各シート片の繊維方向をランダムに配向させた状態で、かつ、各シート片同士が重なり合うように二次元方向に並べた状態でマトリックス樹脂(Ｍ)により接着して形成されている一方、
    前記ＣＦＲＰ層(Ｓ)の裏面層または中間層のＵＤシート片(Ｑ)(Ｑ)…が矩形状であるのに対し、表面層のＵＤシート片(Ｐ)(Ｐ)…が、裏面層または中間層のＵＤシート片(Ｑ)よりも平均厚みが小さく、かつ、少なくとも一部に非矩形状に歪んだシート片を含んで構成されていることを特徴とするＣＦＲＰシート。     In a CFRP sheet having a transparent resin layer (C) formed outside the surface layer of the CFRP layer (S),
    A plurality of UD sheet pieces formed by bonding and integrating a matrix resin (M) in a state where the CFRP layer (S) has continuous fibrous carbon fibers (F) (F). In the state where the fiber direction of each sheet piece is randomly oriented, and, while being adhered by the matrix resin (M) in a state where each sheet piece is arranged in a two-dimensional direction so as to overlap each other,
    The UD sheet pieces (Q) (Q)... Of the back layer or the intermediate layer of the CFRP layer (S) are rectangular, whereas the UD sheet pieces (P) (P). A CFRP sheet characterized in that it has a smaller average thickness than the UD sheet piece (Q) of the intermediate layer and at least partially includes a non-rectangularly distorted sheet piece.
  2. 　ＣＦＲＰ層(Ｓ)の表面層の外側に透明樹脂層(Ｃ)が形成されて成るＣＦＲＰシートにおいて、
    前記ＣＦＲＰ層(Ｓ)が、連続繊維状の炭素繊維(Ｆ)(Ｆ)…を長さ方向に揃えて配列した状態でマトリックス樹脂(Ｍ)により接着一体化して成る多数のＵＤシート片を、各シート片の繊維方向をランダムに配向させた状態で、かつ、各シート片同士が重なり合うように二次元方向に並べた状態でマトリックス樹脂(Ｍ)により接着して形成されている一方、
    前記ＣＦＲＰ層(Ｓ)の表面層及び裏面層のＵＤシート片(Ｐ)(Ｑ)…が非矩形状に歪んだシート片を含んで構成されていることを特徴とするＣＦＲＰシート。     In a CFRP sheet having a transparent resin layer (C) formed outside the surface layer of the CFRP layer (S),
    A plurality of UD sheet pieces formed by bonding and integrating a matrix resin (M) in a state where the CFRP layer (S) has continuous fibrous carbon fibers (F) (F). In the state where the fiber direction of each sheet piece is randomly oriented, and, while being adhered by the matrix resin (M) in a state where each sheet piece is arranged in a two-dimensional direction so as to overlap each other,
    The CFRP sheet characterized in that the UD sheet pieces (P), (Q),... Of the front layer and the back layer of the CFRP layer (S) include sheet pieces that are distorted in a non-rectangular shape.
  3. 　ＣＦＲＰ層(Ｓ)の表面層における非矩形状に歪んだＵＤシート片(Ｐ)の割合が30％以上であることを特徴とする請求項１または２に記載のＣＦＲＰシート。 The CFRP sheet according to claim 1 or 2, wherein the ratio of the non-rectangularly distorted UD sheet piece (P) in the surface layer of the CFRP layer (S) is 30% or more.
  4. 　ＣＦＲＰ層(Ｓ)の表面層におけるＵＤシート片(Ｐ)の一つ当たりの平均面積が、裏面層または中間層のＵＤシート片(Ｑ)の平均面積よりも大きいことを特徴とする請求項１～３の何れか一つに記載のＣＦＲＰシート。 The average area per one UD sheet piece (P) in the surface layer of the CFRP layer (S) is larger than the average area of the UD sheet piece (Q) in the back layer or the intermediate layer. 4. The CFRP sheet according to any one of items 1 to 3.
  5. 　ＣＦＲＰ層(Ｓ)の表面層のＵＤシート片(Ｐ)における並列する炭素繊維同士が部分的に分離した解け部(Ｌ)の割合が、裏面層または中間層のＵＤシート片(Ｑ)よりも大きいことを特徴とする請求項１～４の何れか一つに記載のＣＦＲＰシート。 In the UD sheet piece (P) of the surface layer of the CFRP layer (S), the ratio of the unraveled portion (L) in which the parallel carbon fibers are partially separated from each other is smaller than that of the UD sheet piece (Q) of the back layer or the intermediate layer. The CFRP sheet according to any one of claims 1 to 4, wherein the CFRP sheet is large.
  6. 　ＣＦＲＰ層(Ｓ)のマトリックス樹脂に、透明樹脂層(Ｃ)の熱可塑性樹脂と密着性を有する熱可塑性樹脂が使用されていることを特徴とする請求項１～５の何れか一つに記載のＣＦＲＰシート。 The thermoplastic resin having adhesiveness to the thermoplastic resin of the transparent resin layer (C) is used as the matrix resin of the CFRP layer (S). CFRP sheet.
  7. 　請求項１または２記載のＣＦＲＰシートが同種材料または異種材料の表面に積層一体化されていることを特徴とするＣＦＲＰシートを用いた積層体。 A laminate using a CFRP sheet, wherein the CFRP sheet according to claim 1 or 2 is laminated and integrated on the surface of the same material or a different material.
  8. 　ＣＦＲＰシートの製造方法において、二次元方向に並べた多数のＵＤシート片と透明樹脂層の材料である樹脂フィルムとをロール成形して仮接着することにより、或いは二次元方向に並べた多数のＵＤシート片に透明樹脂層の材料である溶融樹脂をコーティングして熱プレスすることによりＣＦＲＰ層と透明樹脂層が一体となった中間シート材を作製した後、この中間シート材を更に熱プレスすることにより表面層のＵＤシート片を歪ませることを特徴とするＣＦＲＰシートの製造方法。 In a method of manufacturing a CFRP sheet, a large number of UD sheets arranged in a two-dimensional direction are formed by roll-forming and temporarily bonding a large number of UD sheet pieces arranged in a two-dimensional direction and a resin film as a material of a transparent resin layer. A sheet piece is coated with a molten resin, which is a material of a transparent resin layer, and hot-pressed to produce an intermediate sheet material in which the CFRP layer and the transparent resin layer are integrated, and then the intermediate sheet material is further hot-pressed. A method for producing a CFRP sheet, wherein the UD sheet piece of the surface layer is distorted by the method.
  9. 　中間シート材に対する熱プレスの加圧力を、ＵＤシート片と樹脂フィルムを仮接着する際のロール成形の加圧力、或いは溶融樹脂がコーティングされたＵＤシート片に対する熱プレスの加圧力よりも大きくすることを特徴とする請求項８記載のＣＦＲＰシートの製造方法。 The pressing force of the hot press on the intermediate sheet material is larger than the pressing force of the roll forming when the UD sheet piece and the resin film are temporarily bonded, or the pressing force of the hot press on the UD sheet piece coated with the molten resin. The method for producing a CFRP sheet according to claim 8, wherein:
  10. 　ＣＦＲＰシートの製造方法において、連続繊維状の炭素繊維と熱可塑性樹脂とをロール成形することにより炭素繊維同士を接着してＵＤシートを作製すると共に、このＵＤシートを矩形状に裁断して作製されたＵＤシート片を透明樹脂層の材料である樹脂フィルム上に二次元方向に配置して、或いは二次元方向に並べた多数のＵＤシート片に透明樹脂層の材料である溶融樹脂をコーティングして加熱圧縮成形することにより表面層のＵＤシート片を歪ませることを特徴とするＣＦＲＰシートの製造方法。 In the method for producing a CFRP sheet, a continuous fiber carbon fiber and a thermoplastic resin are roll-formed to form a UD sheet by adhering the carbon fibers to each other and cut the UD sheet into a rectangular shape. UD sheet pieces are arranged two-dimensionally on a resin film that is a material of a transparent resin layer, or a number of UD sheet pieces arranged in a two-dimensional direction are coated with a molten resin that is a material of a transparent resin layer. A method for producing a CFRP sheet, wherein a UD sheet piece of a surface layer is distorted by heat compression molding.
  11. 　樹脂フィルムの目付量が、ＵＤシート片全体の目付量に対して5％以上の大きさであることを特徴とする請求項８～１０の何れか一つに記載のＣＦＲＰシートの製造方法。 The method for producing a CFRP sheet according to any one of claims 8 to 10, wherein the basis weight of the resin film is at least 5% of the basis weight of the entire UD sheet piece.
PCT/JP2019/026365 2018-07-03 2019-07-02 Cfrp sheet, laminated body using cfrp sheet, and cfrp sheet production method WO2020009125A1 (en)

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