WO2020158915A1

WO2020158915A1 - Method for manufacturing laminated composite material, method for manufacturing bag, three dimensional structure, and bag

Info

Publication number: WO2020158915A1
Application number: PCT/JP2020/003637
Authority: WO
Inventors: 光出岩田
Original assignee: Ｐｃｊ株式会社
Priority date: 2019-01-31
Filing date: 2020-01-31
Publication date: 2020-08-06
Also published as: WO2020157894A1

Abstract

Provided is a manufacturing method which makes it possible to efficiently manufacture a laminated composite material that comprises carbon fiber reinforced plastic and has excellent design properties.　A method for manufacturing a laminated composite material comprising at least a carbon fiber reinforced plastic layer and a thermoplastic resin layer, said method characterized by comprising: a step for laminating, in a mold and in the following order, a release sheet RP and a laminate sheet body (thermoplastic resin sheet PU1, carbon prepreg CFP1, thermoplastic resin sheet PU2, carbon prepreg CFP2) having a carbon prepreg with a themoplastic resin sheet PU1 layered on at least one surface thereof, such that the release sheet RP and the thermoplastic resin sheet PU1 are in contact; and a step for thermo-compression bonding the sheets that have been laminated in the mold.

Description

Laminated composite material manufacturing method, bag manufacturing method, three-dimensional molded article and bag

The present invention relates to a method for producing a laminated composite material containing carbon fiber reinforced plastic, a method for producing a bag, a three-dimensional molded article, and a bag.

Carbon fiber reinforced plastic (CFRP) is an excellent material that has low density and high strength as compared with metal materials, so it has a problem of high manufacturing cost, but it is widely used as a structural material in various fields. ing.
Prior arts relating to such carbon fiber reinforced plastics are disclosed in Patent Documents 1 to 3.

JP-A-02-169633 Japanese Patent Laid-Open No. 10-138354 JP, 2013-202923, A

Carbon fiber reinforced plastics have come to be used on the basis of their mechanical characteristics that they are lightweight but have high strength, but thereafter, they are also used based on their design. That is, the design property is found in the pattern that appears when the carbon fiber is woven, and this is utilized in design.
As described above, as the emphasis is placed on the design use, it is required to efficiently produce a laminated composite material containing a carbon fiber reinforced plastic having a better design.

In view of the above points, the present invention is to provide a manufacturing method capable of efficiently manufacturing a laminated composite material including a carbon fiber reinforced plastic, which is more excellent in designability. And

(Structure 1)
A method for producing a laminated composite material having at least a carbon fiber reinforced plastic layer and a thermoplastic resin layer, comprising: a mold release sheet, and a carbon prepreg in which a thermoplastic resin sheet is laminated on at least one surface. A laminated sheet body having, in this order, a step of laminating the release sheet and the thermoplastic resin sheet in contact with each other, and a step of thermocompression-bonding each sheet laminated to the molding die, A method for manufacturing a laminated composite material, which comprises:

(Configuration 2)
The forming die is a female die, and a preform die having a corresponding male die shape is used, and the laminated sheet body and the release sheet are laminated in this order on the preform die. The method for manufacturing a laminated composite material according to the constitution 1, further comprising: a step and a step of integrally fitting the laminated sheets into the molding die.

(Structure 3)
The method for producing a laminated composite material according to Configuration 2, wherein a reference position for arranging a sheet serving as an uppermost layer when the preform die is laminated on the forming die is described. ..

(Structure 4)
The method for producing a laminated composite material according to any one of configurations 1 to 3, wherein the release sheet is previously attached to the thermoplastic resin sheet.

(Structure 5)
The laminated sheet body is one in which a first thermoplastic resin sheet, a first carbon prepreg, a second thermoplastic resin sheet, and a second carbon prepreg are laminated in this order. 5. The method for manufacturing a laminated composite material according to any one of configurations 1 to 4.

(Structure 6)
The method for producing a laminated composite material according to the constitution 5, wherein the second thermoplastic resin sheet is formed of a resin having an elastomeric property.

(Structure 7)
7. The method for manufacturing a laminated composite material according to constitution 5 or 6, wherein the second carbon prepreg is composed of a flat sheet and a side sheet which is separate from the flat sheet.

(Structure 8)
8. The method for manufacturing a laminated composite material according to the configuration 7, wherein the flat sheet and the side sheet are partially overlapped with each other.

(Configuration 9)
The thickness of the first thermoplastic resin sheet is larger than that of the first carbon prepreg or the second carbon prepreg, and the thickness of the second thermoplastic resin sheet is the first carbon prepreg or the first carbon prepreg. 9. The method for producing a laminated composite material according to any one of configurations 5 to 8, which is thinner than the carbon prepreg of No. 2.

(Configuration 10)
10. The method for producing a laminated composite material according to any one of configurations 1 to 9, wherein a coating layer having a film thickness smaller than the surface roughness Rz of the release sheet is formed on the surface of the laminated composite material.

(Configuration 11)
11. The method for producing a laminated composite material according to the constitution 10, wherein the coating layer is formed of an antistatic agent or a water repellent.

(Configuration 12)
12. The method for manufacturing a laminated composite material according to the constitution 10 or 11, wherein the coating layer is formed of a fluororesin.

(Configuration 13)
13. The method for manufacturing a laminated composite material according to any one of configurations 1 to 12, wherein the surface roughness Ra of the release sheet is 0.5 μm to 1.0 μm.

(Configuration 14)
The method for manufacturing a laminated composite material according to any one of configurations 1 to 13, wherein a storage portion and a lid portion of the bag are formed, and the storage portion and the lid portion are joined so as to be openable and closable. ..

(Structure 15)
A three-dimensional molded article having a flat surface portion and a side surface portion, comprising a first thermoplastic resin layer, a first carbon fiber reinforced plastic layer, a second thermoplastic resin layer, and a second carbon fiber reinforced plastic layer. The second carbon fiber reinforced plastic layer is formed by bonding the flat carbon fiber reinforced plastic material and the side surface carbon fiber reinforced plastic material, which is separate from the flat carbon fiber reinforced plastic material. A three-dimensional molded article characterized by being formed.

(Configuration 16)
16. The three-dimensional molded article according to structure 15, wherein the flat surface carbon fiber reinforced plastic material and the side surface carbon fiber reinforced plastic material are partially overlapped with each other.

(Configuration 17)
17. The laminated composite material according to Structure 15 or 16, wherein the surface of the first thermoplastic resin layer has a coating layer having a film thickness thinner than the surface roughness Rz of the first thermoplastic resin layer. Three-dimensional molded article.

(Structure 18)
18. The three-dimensional molded article according to Structure 17, wherein the coating layer is formed of an antistatic agent or a water repellent agent.

(Structure 19)
19. The three-dimensional molded article according to Structure 17 or 18, wherein the coating layer is made of a fluororesin.

(Configuration 20)
A bag in which a lid portion and a storage portion are openably and closably joined to each other, wherein the lid portion or the storage portion is formed by the three-dimensional molded article according to any one of configurations 15 to 19.

According to the method for producing a laminated composite material of the present invention, it becomes possible to efficiently produce a laminated composite material having a better design.

The figure which shows the shaping|molding die used for the manufacturing method of the laminated composite material of Embodiment 1 which concerns on this invention. The figure which shows the preform type|mold used for the manufacturing method of the laminated composite material of Embodiment 1. The figure which shows each sheet|seat used for the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. Explanatory drawing which shows the manufacturing method of the laminated composite material of Embodiment 1. The figure which shows the lid part of the bag formed of the laminated composite material of Embodiment 1. The figure which shows the storage part of the bag formed with the laminated composite material of Embodiment 1. The figure which shows the bag formed of the laminated composite material of Embodiment 1. Explanatory drawing of the coating layer of the laminated composite material of Embodiment 2.

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings. In addition, the following embodiment is one mode for embodying the present invention, and does not limit the present invention within the scope thereof.

<Embodiment 1>
The present embodiment relates to a method for producing a laminated composite material that forms a three-dimensional molded article from a laminated composite material having a carbon fiber reinforced plastic layer and a thermoplastic resin layer, and will be described using a bag lid as a specific example of the three-dimensional molded article. To do.

FIG. 1 is a view showing a molding die used in the method for manufacturing a laminated composite material (carbon fiber reinforced composite material) of the present embodiment, and FIG. 2 is a view showing a preform die. The laminated composite material of the present embodiment is a laminated structure having a carbon fiber reinforced plastic layer and a thermoplastic resin layer, a carbon prepreg and a thermoplastic resin sheet are laminated in a molded state, and this is thermocompression-bonded by an autoclave manufacturing method. It is what is molded. The molding die T is a molding die for laminating the carbon prepreg and the thermoplastic resin sheet in a molding state.
The present embodiment is for manufacturing a lid portion of a travel case as an example of a bag, and the travel case of the present embodiment has a rectangular parallelepiped shape, and the lid portion is compared with an upper surface portion (flat surface portion). It has a shape having a side portion with a low target height as a basic aspect. That is, since there is no bottom surface of the rectangular parallelepiped having a low height, the shape opened to the lower side is the basic mode.
As shown in FIG. 1, a molding die T for molding such a lid portion has a rectangular tray shape, and a carbon prepreg and a thermoplastic resin sheet are laminated along the inner surface thereof. Thus, the lid portion having the above-mentioned shape is formed.

The preform die PT is a tool for increasing the efficiency and precision of the work of laminating the carbon prepreg and the thermoplastic resin sheet on the forming die T in the forming state, and as shown in FIG. , And has a male form corresponding to the forming die T (female die).
On the side surface of the preform die PT, a reference position PT11 for arranging the sheet (the second carbon prepreg CFP2 in the present embodiment) which is the uppermost layer when laminated on the forming die T is written. There is. Further, a reference position PT12 which is a lower limit lower limit position of each sheet (reference position for preventing the sheet edge from exceeding this) is described.
The molding die T in this embodiment is made of carbon fiber reinforced plastic, and the preform die PT is also made of carbon fiber reinforced plastic. The molding die T and the preform die PT are formed of carbon fiber reinforced plastic having a low linear expansion coefficient and high synthesis, so that the accuracy of transferring the laminated sheet body laminated on the preform die PT to the molding die T is improved. Is obtained. Further, since the carbon fiber reinforced plastic is lightweight and has rigidity, it has excellent workability in handling the molding die T and the preform die PT. As a material for forming the molding die T and the preform die PT, an appropriate material such as stainless steel can be appropriately selected.

FIG. 3 is a diagram showing each sheet for forming the laminated composite material of the embodiment.
The laminated composite material of this embodiment includes a first thermoplastic resin layer (polyurethane layer in this embodiment), a first carbon fiber reinforced plastic layer, and a second thermoplastic resin layer (polyurethane layer in this embodiment). It has a four-layer structure of a second carbon fiber reinforced plastic layer, and as a sheet for forming this, a first thermoplastic resin sheet PU1, a first carbon prepreg CFP1, and a second thermoplastic resin sheet The resin sheet PU2 and the second carbon prepreg CFP2 are used.
Further, the release sheet RP is used when laminating the above-mentioned sheets and molding the laminated composite material (lid part) by an autoclave.
Each sheet has a shape in which a notch is formed at each corner of a rectangular shape, and is precut into a shape as a development view of a lid having an upper surface portion and a side surface portion.

The first thermoplastic resin sheet PU1 is a polyurethane sheet having a thickness of 300 μm. The first thermoplastic resin sheet PU1 has translucency. The first thermoplastic resin sheet PU1 is located on the surface side (design surface) as a product (bag), improves the texture and feel of the bag surface, and improves safety (when damaged, etc.). In addition, the carbon fiber is formed to have a thickness of 300 μm, which is sufficient to reduce the protrusion of the carbon fiber to the outside.
Further, the polyurethane layer formed on the design surface by the first thermoplastic resin sheet PU1 also has a function as a coating surface, which enables commercialization without coating. Conventionally, carbon fiber reinforced plastics have fine bubbles on the surface during manufacturing, which makes it difficult to cleanly coat the surface (requiring multiple layers of coating, which is very costly). However, according to the present embodiment, since the polyurethane layer is formed on the surface, a separate coating process can be eliminated. It is of course possible to apply the coating to the polyurethane layer formed on the design surface by the first thermoplastic resin sheet PU1. Since the polyurethane layer covers the air bubbles on the surface of the carbon fiber reinforced plastic, a beautiful painted surface can be easily obtained.

The release sheet RP is disposed between the first thermoplastic resin sheet PU1 and the molding die T to protect the surface of the first thermoplastic resin sheet PU1 and improve the design of the surface. And is formed of heat-resistant paper.
Since the first thermoplastic resin sheet PU1 is arranged on the side in contact with the molding die T, if the molding die T has a slight scratch or the like, this scratch is transferred when thermocompression-bonded in the autoclave. As a result, it may appear as a scratch on the surface of the first thermoplastic resin layer. Further, if dust or dirt adheres to the mold T, dust or dirt may similarly appear on the surface of the first thermoplastic resin layer. By using the release sheet RP, such a problem can be reduced.
Further, the release sheet RP and the first thermoplastic resin sheet PU1 are laminated and thermocompression-bonded by an autoclave, whereby fine irregularities on the surface of the release sheet RP are transferred, and the surface of the release sheet RP is transferred to the first thermoplastic resin layer. It can give a matte feeling. When the release sheet RP having the arithmetic average roughness Ra of 0.5 μm to 1.0 μm is used, a suitable matte feeling can be formed on the surface of the first thermoplastic resin layer. The arithmetic average roughness Ra is obtained by extracting a part of the roughness curve measured by a roughness meter with a reference length and expressing the unevenness state of the section by an average value.
By using a sheet having a smooth surface as the release sheet RP, the first thermoplastic resin layer may have a glossy surface.
Thus, by using the release sheet RP, it is possible to protect the surface of the first thermoplastic resin sheet PU1 (first thermoplastic resin layer) and improve the design of the surface.
In addition, by using the release sheet RP, it is possible to reduce the damage to the mold T and extend the life of the mold T.
In the present embodiment, the release sheet RP is pre-cut in the state of being attached to the first thermoplastic resin sheet PU1 in advance, and in the working process described below, the release sheet RP is The first thermoplastic resin sheet PU1 is treated integrally.

The second thermoplastic resin sheet PU2 is a polyurethane sheet having a thickness of 150 μm. The second thermoplastic resin sheet PU2 is arranged between the first carbon prepreg CFP1 and the second carbon prepreg CFP2, and after thermocompression bonding, the first carbon fiber reinforced plastic layer and the second carbon fiber reinforced plastic layer. A second thermoplastic resin layer is formed between the layers.
Although carbon fiber reinforced plastic has high strength, it lacks flexibility and tends to be easily cracked by impact. On the other hand, by forming a laminated composite material in which a material layer having an elastomeric property is formed between two carbon fiber reinforced plastic layers, flexibility is imparted while having high strength of the carbon fiber reinforced plastic, Impact resistance is improved. That is, the material layer having the elastomeric property promotes relative slippage between the first carbon fiber reinforced plastic layer and the second carbon fiber reinforced plastic layer, and this phenomenon imparts flexibility to the laminated composite material. The result is obtained. In order to contribute to the purpose, the second thermoplastic resin sheet is preferably made of a resin softer than the matrix resin of the carbon prepreg.

The first carbon prepreg CFP1 and the second carbon prepreg CFP2 are carbon prepregs having a thickness of 200 μm. Therefore, in the present embodiment, the thickness of the first thermoplastic resin sheet PU1 is thicker than the first carbon prepreg CFP1 and the second carbon prepreg CFP2, and the thickness of the second thermoplastic resin sheet PU2 is It is thinner than the first carbon prepreg CFP1 and the second carbon prepreg CFP2.
The first carbon prepreg CFP1 has the same shape as each of the other sheets.
On the other hand, the second carbon prepreg CFP2 is composed of a flat sheet CFP25 and side sheets CFP21 to CFP24 which are separate from the flat sheet CFP25. That is, the flat sheet CFP25 forming the upper surface of the lid and the side sheets CFP21 to CFP24 forming the side surfaces of the lid are formed as separate bodies. As will be described later, the flat surface sheet CFP25 and the side surface sheets CFP21 to CFP24 are joined by being partially overlapped with each other on the side where they are joined, and thus they are partially overlapped and joined together. In this state, the sheet has the same shape as the other sheets.

Next, a method for manufacturing the laminated composite material (bag portion) of the present embodiment will be described with reference to FIGS.
As a rough work flow,
A second carbon prepreg CFP2, a second thermoplastic resin sheet PU2, a laminated sheet body of the first carbon prepreg CFP1 and the first thermoplastic resin sheet PU1, and a release sheet RP with respect to the preform type PT. , A step of stacking in this order,
A step of integrally removing each sheet laminated on the preform PT from the preform PT,
By fitting the detached laminated body of the respective sheets into the mold T, the release sheet RP, the first thermoplastic resin sheet PU1, the first carbon prepreg CFP1, and the second thermoplastic sheet Stacking the resin sheet PU2 and the second carbon prepreg CFP2 on the molding die T in this order;
Are sequentially performed.
By fitting a laminated body of the respective sheets laminated on the preform mold PT into the molding die T, the release sheet RP and the carbon on which the thermoplastic resin sheet PU1 is laminated on one surface of the molding die T. The laminated sheet body having the prepreg is laminated in this order so that the release sheet RP and the thermoplastic resin sheet PU1 are in contact with each other.

4 to 6 are views for explaining the work of arranging the second carbon prepreg CFP2 on the preform PT.
As described above, the second carbon prepreg CFP2 is composed of the flat sheet CFP25 and the side sheets CFP21 to CFP24 which are separate from the flat sheet CFP25.
As shown in FIG. 4, first, the side surface sheet CFP21 (side surface in the longitudinal direction) is arranged with respect to the preform mold PT. A reference position PT11 for disposing the second carbon prepreg CFP2 is marked on the side surface of the preform mold PT, and the side surface sheet CFP21 is aligned with the reference position PT11 with respect to the preform mold PT. Deploy.
The side surface sheet CFP21 has a height dimension that covers the corner portion of the preform mold PT (that is, the corner portion of the bag lid) and reaches the upper surface portion. This is the same for the side surface sheets CFP21 to CFP24.
Similarly to the side face sheet CFP21, the side face sheet CFP22 (side face in the longitudinal direction) on the other end side is arranged with respect to the preform mold PT (not shown).
Note that the carbon prepreg and the thermoplastic resin sheet have adhesiveness to some extent by themselves, and based on the adhesiveness, they can be attached to the preform type PT or attached when laminating each sheet. Done.

Next, as shown in FIG. 5, the side surface sheet CFP23 (side surface in the lateral direction) is arranged with respect to the preform mold PT. Similar to the side face sheet CFP21, the side face sheet CFP23 is arranged with respect to the preform PT in accordance with the reference position PT11.
Further, similarly to the side face sheet CFP23, the side face sheet CFP24 (side face in the lateral direction) on the other end side is arranged with respect to the preform mold PT (not shown).
In the present embodiment, as shown in FIG. 5B, the side surface sheets CFP21 and 22 (side surfaces in the longitudinal direction) and the side surface sheets CFP23 and 24 (side surfaces in the lateral direction) are respectively near the corners. Are arranged so that the ends of the butt against each other.

Next, as shown in FIG. 6, the flat sheet CFP25 is placed on the preform mold PT. In the disposition of the flat sheet CFP25, the cutout portions of the corners are aligned with the reference position PT11, and the flat sheet CFP25 is arranged so that the flat sheet CFP25 is pasted from the center to the side surface.
The flat sheet CFP25 has a size that covers the corners of the preform mold PT (that is, the corners of the lid of the bag) and reaches the side surfaces.

By separating the flat sheet CFP25 and the side sheets CFP21 to CFP24 from each other, workability in arranging the sheet with respect to the preform mold PT (or the molding mold T) is excellent, and wrinkles at corners and It is also possible to reduce the occurrence of slipperiness (that does not follow the mold). In addition, each of the side surface sheets CFP21 to CFP24 can be formed from, for example, an end material after cutting the other sheets, which is excellent in material use efficiency.
In addition, as described above, the flat sheet CFP25 and the side sheets CFP21 to CFP24 are partially overlapped and bonded to each other, whereby the carbon prepreg is laminated at the corners, and the strength of the corners is improved. .. In a bag having a substantially rectangular parallelepiped shape such as a travel case, loads are often applied to the corners. On the other hand, according to the above configuration, the strength of the corner portion is enhanced, which is preferable.
Note that, here, in the arrangement of the side surface sheets CFP21 to 24, the side surface sheets CFP21 to 24 are arranged in order, but the side surface sheets CFP21 to CFP24 may be arranged in any order. .. Further, the flat sheet CFP25 may be arranged first, and then the side sheet CFP21 to 24 may be arranged.

Next, as shown in FIG. 7, the second thermoplastic resin sheet PU2 is placed on the preform PT to which the second carbon prepreg CFP2 is attached.
The second thermoplastic resin sheet PU2 is aligned by aligning the outer peripheral shape of the second carbon prepreg CFP2 (or the reference position PT11 of the preform mold PT) with the outer peripheral shape of the second thermoplastic resin sheet PU2. Done by

Next, the first carbon prepreg CFP1 is placed on the preform mold PT in which the second carbon prepreg CFP2 and the second thermoplastic resin sheet PU2 are laminated in this order.
The alignment of the first carbon prepreg CFP1 is performed by aligning the outer peripheral shape of each laminated sheet (or the reference position PT11 of the preform mold PT) with the outer peripheral shape of the first carbon prepreg CFP1.
In the arrangement of the first carbon prepreg CFP1, as shown in FIG. 8, the short sides of the preform mold PT are arranged on the upper side and the lower side, and the long sides are arranged on the left side and the right side. The carbon fiber of the carbon prepreg CFP1 of No. 1 is arranged so that the mesh direction of the carbon prepreg CFP1 rises to the right.

Next, the release sheet RP is attached to the preform die PT in which the second carbon prepreg CFP2, the second thermoplastic resin sheet PU2, and the first carbon prepreg CFP1 are laminated in this order. The thermoplastic resin sheet PU1 is arranged. At this time, as shown in FIG. 9, the release sheet RP is placed on the upper surface side and the second thermoplastic resin sheet PU2 is placed on the preform PT side.
The alignment of the first thermoplastic resin sheet PU1 to which the release sheet RP is attached is performed by aligning the outer peripheral shape of each laminated sheet (or the reference position PT11 of the preform die PT) with the release sheet RP. This is performed by matching the outer peripheral shapes of the attached first thermoplastic resin sheet PU1.

Next, by the above steps, the second carbon prepreg CFP2, the second thermoplastic resin sheet PU2, the first carbon prepreg CFP1, the first thermoplastic resin sheet PU1, and the release sheet RP are formed on the preform mold PT. The laminated body laminated in this order is peeled off integrally from the preform die PT and fitted into the forming die T (FIG. 10).
As shown in FIG. 10, the laminate is turned upside down and exchanged so that the mold release sheet RP, the thermoplastic resin sheet PU1, the first carbon prepreg CFP1, and the second heat are exchanged in the mold T. The plastic resin sheet PU2 and the second carbon prepreg CFP2 are laminated in this order.
The placement of each sheet in the forming die T, which is a female die, makes it difficult to fit each sheet firmly to the shape of the die, especially at the corners and the like, which is a complicated work, but in the present embodiment, By using the male preform mold PT, the workability is excellent, and each sheet can be arranged neatly along the mold firmly.

As described above, the respective sheets are laminated in the forming state in the forming die T, the sheets are formed by thermocompression bonding by the autoclave manufacturing method, and the formed article is released from the forming die T, so that the three-dimensional structure formed by the laminated composite material is formed. A lid part which is a molded product is obtained.
Note that each method can be appropriately used for autoclave molding. Autoclave molding is a well-known technique, and a description thereof is omitted here, but during thermocompression bonding, the degree of vacuum of the bag containing the laminated composite material is kept (the pressure bonding state is maintained) until the temperature becomes 80 degrees or less. Is preferred. In the laminated composite material of the present embodiment, a thermoplastic resin is used, and if the degree of vacuum is relaxed at a temperature higher than 80 degrees, unevenness may occur in the transfer of matte feeling by the release paper RP. Is.

FIG. 11 is a plan view showing the lid portion 11 molded as described above.
Further, FIG. 12 shows plan views of the storage portion 12 of the bag (travel case). The storage portion 12 has a laminated structure similar to that of the lid portion 11, and is formed by the same manufacturing process as that of the lid portion 11 described above. Although there is a difference in the shape of the mold due to the difference in the shapes of the lid portion 11 and the storage portion 12 and the difference in the shape of each sheet, each sheet is laminated using a preform mold, and the laminated body thus laminated is It is to be transferred to a molding die, and since the concept is similar to that of manufacturing the lid portion 11, detailed description thereof is omitted here.

FIG. 13 shows the bag 1 formed using the lid 11 and the storage 12.
In the bag 1, the lid 11 and the storage 12 are fitted with various parts such as corners, lined, and the like, and further, metal fittings such as fasteners (keys), handles, ornaments, etc. It is formed by mounting and joining the lid portion 11 and the housing portion 12 so as to be openable and closable by a hinge 13.

In the present embodiment, regarding the belt to be attached to the bag, the thermoplastic resin sheet is provided on the upper surface and the lower surface of the carbon fiber woven fabric made of carbon fibers (in the present embodiment, the upper surface side (design surface side) has a thickness of 300 μm, A laminated composite material is used, which is formed by thermocompressing a polyurethane sheet having a thickness of 150 μm on the lower surface side.
"Carbon fiber woven fabric woven from carbon fibers" is one in which there is no matrix resin of carbon prepreg. The laminated composite material, in which the translucent thermoplastic resin sheet is thermo-compressed on both sides of this, becomes a material that is very soft and has a leather-like feel, and the surface looks like a carbon material (carbon fiber reinforced plastic). The same is true. In other words, it is a material that looks like a carbon material and has a high-class feel with a texture close to leather.
By forming a belt to be attached to the bag 1 with such a material, the appearance of the carbon material of the lid portion 11 and the storage portion 12 can be matched, and a product with a higher quality can be obtained. In addition to the belt, the above-mentioned laminated composite material may be used for each part used for the bag 1 (each part applied to the corners and the like of the lid 11 and the storage part 12, a handle, etc.). Of course, each part used for the bag 1 such as a belt may be made of another material (such as leather).

As described above, according to the present embodiment, by using the preform mold PT, the work of stacking the carbon prepreg and the thermoplastic resin sheet on the mold T in the molded state can be made efficient and highly accurate. it can.
Further, since the reference position PT11 is marked on the preform PT, the sheets can be arranged with high accuracy.

According to this embodiment, by using the release sheet RP disposed between the first thermoplastic resin sheet PU1 and the molding die T, the surface of the first thermoplastic resin sheet PU1 is protected and The design of the surface can be improved. Further, by using the release sheet RP, it is possible to reduce the damage to the molding die T and extend the life of the molding die T.

According to the present embodiment, since the first thermoplastic resin layer is formed on the surface of the carbon material (first carbon fiber reinforced plastic layer), the texture and feel of the surface are improved and the safety is improved. can do. Further, it is not necessary to paint the surface, and a beautiful painted surface can be easily obtained even when the surface is painted.
Moreover, impact resistance is improved by adopting a structure in which the thermoplastic resin layer having elastomeric properties is disposed between the two carbon fiber reinforced plastic layers.

According to the present embodiment, the second carbon prepreg CFP2 is composed of the flat sheet CFP25 and the side sheets CFP21 to CFP24 which are separate from the flat sheet CFP25. It excels in workability when arranging it, and it also excels in material usage efficiency. In addition, the flat sheet CFP25 and the side sheets CFP21 to CFP24 are partially overlapped and bonded to each other to form a structure in which carbon prepregs are laminated at the corners.
By thermocompression-bonding this, a structure in which the flat surface carbon fiber reinforced plastic material and the side surface carbon fiber reinforced plastic material are laminated in the corner portion improves the strength of the corner portion.

In the present embodiment, the laminated composite material has a four-layer structure of a first thermoplastic resin layer, a first carbon fiber reinforced plastic layer, a second thermoplastic resin layer and a second carbon fiber reinforced plastic layer. However, the present invention is not limited to this, and may be "a laminated composite material having at least a carbon fiber reinforced plastic layer and a thermoplastic resin layer". For example, the number of repetitions of the thermoplastic resin layer and the carbon fiber reinforced plastic layer may be increased or decreased, or another material layer (for example, a coating film) may be provided.
In this embodiment, since the surface (design surface) of the laminated composite material as a product is only one side (the other (inner surface) side is lined), the surface of the second carbon fiber reinforced plastic layer is Although the thermoplastic resin layer is not laminated, in a product or the like in which both sides of the material are design surfaces, the thermoplastic resin layer may be laminated on both sides. In that case, it is preferable to dispose release sheets on both sides in the manufacturing process.

Further, in the present embodiment, polyurethane is taken as an example of the thermoplastic resin, but the present invention is not limited to this. For the thermoplastic resin layer disposed between the two carbon fiber reinforced plastic layers, various resins having elastomeric properties and softer than the matrix resin of the carbon fiber reinforced plastic can be used.
Further, for the thermoplastic resin layer provided on the surface (design surface) side, various resins can be used according to the design concept such as design, texture, touch and safety.

In the present embodiment, the lid portion (and the storage portion) of the bag has been described as an example of the three-dimensional molded item, but the present invention is not limited to the bag and can be applied to various three-dimensional molded items.

In the present embodiment, the example in which the laminated body laminated on the preform mold is peeled from the preform mold and put in the molding die is described as an example, but if the mold release property between the preform mold and the laminated body is good. Alternatively, a process of putting the laminated body laminated on the preform mold into the molding die and removing only the preform mold in this state may be performed. Alternatively, the laminated body laminated on the preform mold may be put into a molding die and, as it is (for each preform mold), thermocompression bonding by autoclave molding may be performed. However, in these cases, the releasability between the preform mold and the laminate must be good. In order to improve releasability, a release sheet may be provided between the preform mold and the laminate.

<Embodiment 2>
In the second embodiment, a coating layer is provided on the surface of the laminated composite material described in the first embodiment. More specifically, the fine roughness of the surface of the release sheet RP is transferred, and the surface roughness Rz of the release sheet RP is more than the surface roughness Rz of the surface of the first thermoplastic resin layer which is the surface having the fine unevenness. Also has a thin coating layer.

FIG. 14: is a figure for demonstrating the coating layer of the laminated composite material of this embodiment.
FIG. 14A is a schematic view showing the unevenness of the surface of the laminated composite material described in the first embodiment. As shown in the figure, the surface S of the laminated composite material described in the first embodiment has unevenness due to the unevenness of the surface of the release sheet RP being transferred, whereby light is diffusely reflected and matted. It gives a feeling. Rz in the figure indicates the maximum height as the surface roughness. The surface roughness Rz is a value of the sum of the highest part and the deepest part obtained by extracting a part of the roughness curve measured by a roughness meter with a reference length. The unevenness of the surface S of the laminated composite material is the unevenness of the surface of the release sheet RP transferred, and the surface roughness Rz of the surface S of the laminated composite material is equal to the surface roughness Rz of the release sheet RP. It is formed as follows.

The unevenness of the surface S gives a matte feel, but the unevenness of the surface tends to cause stains such as fingerprints to be easily attached and difficult to remove.
The laminated composite material of the present embodiment has a coating layer on the surface thereof, so that stains such as fingerprints can be made inconspicuous and easy to be removed, and at the same time, the matte feeling can be maintained.

FIG. 14B is a conceptual diagram showing the coating layer Cl on the surface of the laminated composite material of the present embodiment.
The coating layer Cl is formed of a fluororesin which is an antistatic agent and a water repellent (for example, “Capron GS-5” manufactured by Nisshin Scientific Research Institute Co., Ltd. can be used) and has a light-transmitting property. There is. The coating layer Cl is formed by spraying the diluted fluororesin liquid on the surface of the laminated composite material described in Embodiment 1, wiping off the excess with a waste cloth, and then drying.
By wiping off the fluororesin liquid before drying with a waste cloth having fine irregularities on the surface of the cloth or the like, the fluororesin liquid is wiped off so as to enter the irregularities on the surface S of the laminated composite material. As a result, as shown in FIG. 14B, the coating layer Cl having a film thickness smaller than the surface roughness Rz of the surface S of the laminated composite material is formed.
In the manufacturing of the bag described in the first embodiment, the step of forming the coating layer Cl is performed in the state of the lid portion 11 and the storage portion 12 shown in FIGS. 11 and 12, that is, each of the bags. The step of forming the coating layer Cl in the state of the molded component as the laminated composite material may be performed before the parts are attached, but the coating layer Cl may be formed after the parts are attached.

FIG. 14C shows a case where the coating layer Cl′ having a film thickness Th that is thicker than the surface roughness Rz of the surface S of the laminated composite material is formed.
In FIG. 14C, the surface is smoothed by the coating layer Cl′. In this case, although it is effective in suppressing the adhesion of dirt and facilitating the removal of dirt, the matte feeling on the surface is lost.

On the other hand, according to the present embodiment, by providing the coating layer Cl having a film thickness smaller than the surface roughness Rz of the surface S, dirt such as fingerprints can be made inconspicuous and easy to be removed, and a matte feeling can be obtained. Can be lost. In order to obtain a more matte feeling, the surface roughness Ra in the state where the coating layer Cl is formed is preferably 0.5 μm to 1.0 μm, and therefore the surface roughness Ra is the same as that in the first embodiment ( A release sheet larger than 0.5 μm to 1.0 μm) may be used.
Further, in this embodiment, since the coating layer Cl is formed of the fluororesin which is the antistatic agent and the water repellent, the adhesion of dust due to static electricity can be reduced, and the adhesion of dirt can be suppressed and dirt can be easily removed. The effect can be increased.

In the present embodiment, the maximum height Rz is used for the surface roughness of the surface S. However, the arithmetic mean roughness Ra is used to describe “having a film thickness thinner than the surface roughness Ra of the surface S”. The coating layer Cl" may be formed. As described above, the arithmetic average roughness Ra is obtained by extracting a part of the roughness curve measured by the roughness meter with the reference length and expressing the unevenness state of the section by the average value. With respect to the surface roughness Ra of the surface S, a part of a curve showing the difference between the curve representing the surface of the surface S and the curve representing the surface of the coating layer Cl is extracted with a reference length, and the unevenness state of the section is averaged. The one represented by is to be small.
Further, in the present embodiment, the case where the coating layer is made of a fluororesin is taken as an example, but the present invention is not limited to this. For example, a material using a silicon-based coating agent may be used.

1. ．． Bag 11. ．． Lid (three-dimensional molded product)
12. ．． Storage part (three-dimensional molded product)
CFP1. ．． First carbon prepreg CFP2. ．． Second carbon prepreg CFP21-24. ．． Side sheet CFP25. ．． Flat sheet PU1. ．． First thermoplastic resin sheet PU2. ．． Second thermoplastic resin sheet RP. ．． Release sheet T. ．． Mold PT. ．． Preform type PT11. ．． Reference position Cl. ．． Coating layer

Claims

A method for producing a laminated composite material having at least a carbon fiber reinforced plastic layer and a thermoplastic resin layer,
With respect to the molding die, a release sheet and a laminated sheet body having a carbon prepreg in which a thermoplastic resin sheet is laminated on at least one surface, in this order, the release sheet and the thermoplastic resin sheet are in contact with each other. Stacking so that
A step of thermocompression-bonding each sheet laminated to the molding die,
A method for producing a laminated composite material, comprising:
The forming die is a female die, and a preform die having a corresponding male die shape is used, and the laminated sheet body and the release sheet are laminated in this order on the preform die. Steps,
A step of integrally fitting each of the laminated sheets into the molding die;
The method for producing a laminated composite material according to claim 1, further comprising:
3. The laminated composite material according to claim 2, wherein the preform mold is provided with a reference position for arranging a sheet which is an uppermost layer when laminated on the mold. Method.
The method for producing a laminated composite material according to any one of claims 1 to 3, wherein the release sheet is attached to the thermoplastic resin sheet in advance.
The laminated sheet body is one in which a first thermoplastic resin sheet, a first carbon prepreg, a second thermoplastic resin sheet, and a second carbon prepreg are laminated in this order. The method for producing a laminated composite material according to any one of claims 1 to 4.
The method for manufacturing a laminated composite material according to claim 5, wherein the second thermoplastic resin sheet is formed of a resin having an elastomeric property.
The method for producing a laminated composite material according to claim 5 or 6, wherein the second carbon prepreg is composed of a flat sheet and a side sheet which is separate from the flat sheet.
The method for manufacturing a laminated composite material according to claim 7, wherein the flat sheet and the side sheet are partially overlapped with each other.
The thickness of the first thermoplastic resin sheet is larger than that of the first carbon prepreg or the second carbon prepreg, and the thickness of the second thermoplastic resin sheet is the first carbon prepreg or the first carbon prepreg. The method for producing a laminated composite material according to any one of claims 5 to 8, wherein the carbon prepreg is thinner than carbon prepreg 2.
The method for producing a laminated composite material according to claim 1, wherein a coating layer having a film thickness smaller than the surface roughness Rz of the release sheet is formed on the surface of the laminated composite material. ..
The method for producing a laminated composite material according to claim 10, wherein the coating layer is formed of an antistatic agent or a water repellent.
The method for producing a laminated composite material according to claim 10 or 11, wherein the coating layer is formed of a fluororesin.
13. The method for producing a laminated composite material according to claim 1, wherein the surface roughness Ra of the release sheet is 0.5 μm to 1.0 μm.
The method for producing a laminated composite material according to any one of claims 1 to 13, wherein a storage portion and a lid portion of the bag are formed, and the storage portion and the lid portion are joined so as to be openable and closable. Method.
A three-dimensional molded article having a flat surface portion and a side surface portion,
Formed by a carbon fiber reinforced composite material having a first thermoplastic resin layer, a first carbon fiber reinforced plastic layer, a second thermoplastic resin layer and a second carbon fiber reinforced plastic layer,
Three-dimensional molding, wherein the second carbon fiber reinforced plastic layer is formed by joining a flat surface carbon fiber reinforced plastic material and a side surface carbon fiber reinforced plastic material which is separate from the flat surface carbon fiber reinforced plastic material. Stuff.
The three-dimensional molded article according to claim 15, characterized in that the planar carbon fiber reinforced plastic material and the lateral carbon fiber reinforced plastic material are partially overlapped with each other.
The three-dimensional molding according to claim 15 or 16, wherein the surface of the first thermoplastic resin layer has a coating layer having a film thickness smaller than the surface roughness Rz of the first thermoplastic resin layer. Stuff.
The three-dimensional molded article according to claim 17, wherein the coating layer is formed of an antistatic agent or a water repellent.
The three-dimensional molded article according to claim 17 or 18, characterized in that the coating layer is formed of a fluororesin.
A bag in which a lid part and a storage part are openably and closably joined,
A bag characterized in that the lid portion or the storage portion is formed of the three-dimensional molded article according to any one of claims 15 to 19.