JP2015116806A - 熱可塑性樹脂補強シート材及びその製造方法 - Google Patents
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Abstract
【解決手段】熱可塑性樹脂補強シート材1は、複数の補強繊維が所定方向に引き揃えられてシート状に形成されるとともに目付が80g/m2以下の補強繊維シート材2と、繊度が5.6デシテックス〜84デシテックスの熱可塑性樹脂繊維材料からなるとともに目付が5g/m2〜90g/m2の布地3と、布地3の溶融温度より低い温度で溶融又は軟化するとともに補強繊維シート材2及び布地3を離散的に付着させる接着用熱可塑性樹脂材4とを備えている。
【選択図】図1
Description
気孔容積率 P=(M−B)/M ×100(%)
B:見かけ比重=A/(1000×T)
気孔容積率は、50%以上に設定されることが好ましく、より好ましくは80%以上である。こうした空隙の多い布地を使用することで、補強繊維シート材に熱可塑性樹脂材料が含浸する際にシート材内部の空気が布地の空隙を通って排気されて効率よく脱気を行うことができるので、ボイドの発生を抑止することが可能となる。布地に形成された空隙は、できるだけ均一に分布していることが好ましく、編組織又は織組織により布地の空隙の分布を制御することで、空隙が均一に分布した布地を得ることができる。また、編組織は、伸縮性を備えているため、熱可塑性樹脂補強シート材を3次元形状に形成する場合に、形状に合わせて空隙を保持した状態で伸縮することができる。特に、接着用熱可塑性樹脂材により補強繊維シート材に対して布地が部分的に接着された状態では、編組織の伸縮性が確保されて様々な3次元形状の成型を容易に行うことが可能となる。
(編地1)ナイロン6からなる糸(比重1.14;20デシテックス/1f)を使用して、鎖編+ハーフ編(糸配列○×;1in 1out)で編成した編地(目付17.6g/m2、厚み0.21mm)の場合には、気孔容積率は約92.7%となる。
(編地2)ナイロン6からなる糸(比重1.14;20デシテックス/1f)を使用して、デンビー編+鎖編+挿入糸(糸配列オールイン)で編成した編地(目付18.0g/m2、厚み0.22mm)の場合には、気孔容積率は約92.8%となる。
(編地3)ナイロン6からなる糸(比重1.14;20デシテックス/1f)を使用して、鎖編+1×4サテン(糸配列◎×××;◎は2本入り)で編成した編地(目付19.8g/m2、厚み0.27mm)の場合には、気孔容積率は約93.6%となる。
(編地4)ナイロン6からなる糸(比重1.14;20デシテックス/1f)を使用して、デンビー編+サテン(糸配列オールイン)で編成した編地(目付50.9g/m2、厚み0.23mm)の場合には、気孔容積率は約80.6%となる。
また、織地の場合には、以下のものが挙げられる。
(織地1)ナイロン66からなる糸(比重1.14;10デシテックス/5f)を使用して、平織で織成した織地(目付16.5g/m2、厚み0.18mm)の場合には、気孔容積率は約92.0%となる。
(織地2)ナイロン66からなる糸(比重1.14;15デシテックス/5f)を使用して、平織で織成した織地(目付26.25g/m2、厚み0.27mm)の場合には、気孔容積率は約91.5%となる。
<使用材料>
(補強繊維束に使用した繊維束)
東レ株式会社製;T700SC−60E、繊維直径約7μm、繊維本数12000本
(布地に使用した繊維材料)
INDACHI社製;NYF20D−IFBR、融点220〜240℃
(接着用熱可塑性樹脂材に使用した樹脂)
東洋染工株式会社製;8HS(ポリアミド系樹脂粉末)、融点約100℃
(1)繊維材料を用いて、トリコット編機(カールマイヤ社製)により編成密度65コース/インチで、上記の編地1と同様の布地を編成した。得られた布地は、幅360mmで目付が約18g/m2であり、気孔容積率は、約92.7%であった。布地は供給ロールに巻取り、布地供給機構にセットした。
(2)布地供給機構から布地を繰り出して走行させながら、布地をヒータにより120℃に加熱し、粉体散布装置を用いて、接着用熱可塑性樹脂材を布地表面に離散的に一様に付着させ、布地の単位面積当たり約3.3g/m2の量を仮接着させた。
(3)図3に示す製造工程にて、補強繊維束を12本、24mm間隔でセットし、多数本を同時に空気開繊する多数本繊維束開繊機構及び縦方向振動付与機構にて、各々の補強繊維束を幅24mmの補強繊維開繊糸に開繊し、その後、補強繊維開繊糸を幅方向振動付与機構にて幅方向に振動させて、補強繊維開繊糸間に隙間がない補強繊維シート材を得た。得られた補強繊維シート材は、幅288mm、繊維目付(単位面積あたりの繊維重量)約33g/m2であった。
(4)図3に示すように、得られた補強繊維シート材を布地と重ね合せるように搬送し、加熱ロールの加熱温度を120℃に設定して、補強繊維シート材の片面に布地の仮接着面を密着させながら約10m/分の走行速度で搬送させることで、熱可塑性樹脂補強シート材を製造した。
得られた熱可塑性樹脂補強シート材は、まず、補強繊維シート材を構成する各補強繊維が真直な状態で均一に分散されていた。布地は接着ムラのない一様な接着状態で補強繊維シート材の全面に付着し、補強繊維開繊糸の形態を安定させていた。補強繊維シート材に割れや繊維集束は生じていなかった。また、得られた熱可塑性樹脂補強シート材はカールすることなく平面形状が維持されており、湾曲変形した場合でも柔軟性を有するとともに元の平面状態に戻る復元力を備え、取り扱いが良好であった。
Claims (9)
- 複数の補強繊維が所定方向に引き揃えられてシート状に形成されるとともに目付が80g/m2以下の補強繊維シート材と、繊度が5.6デシテックス〜84デシテックスの熱可塑性樹脂繊維材料からなるとともに目付が5g/m2〜90g/m2の布地と、前記布地の溶融温度より低い温度で溶融又は軟化するとともに前記補強繊維シート材及び前記布地を離散的に付着させる接着用熱可塑性樹脂材とを備えている熱可塑性樹脂補強シート材。
- 前記布地は、気孔容積率が50%以上である請求項1に記載の熱可塑性樹脂補強シート材。
- 前記布地は、編地である請求項1又は2に記載の熱可塑性樹脂補強シート材。
- 前記補強繊維シート材は、断面厚さが前記補強繊維の直径の10倍以内に設定されている請求項1から3のいずれかに記載の熱可塑性樹脂補強シート材。
- 前記接着用熱可塑性樹脂材の付着量は、前記布地の単位面積当たり1g/m2〜10g/m2である請求項1から4のいずれかに記載の熱可塑性樹脂補強シート材。
- 請求項1から5のいずれかに記載の熱可塑性樹脂補強シート材が複数枚積層して形成され、一体化されている熱可塑性樹脂多層補強シート材。
- 前記熱可塑性樹脂補強シート材は、前記補強繊維シート材の引き揃えられた方向がそれぞれ多軸となるように積層されている請求項6に記載の熱可塑性樹脂多層補強シート材。
- 繊度が5.6デシテックス〜84デシテックスの熱可塑性樹脂繊維材料からなるとともに目付が5g/m2〜90g/m2の布地を加熱して当該布地の溶融温度より低い温度で溶融又は軟化する粉体状の接着用熱可塑性樹脂材を当該布地の表面に離散的に仮接着させる仮接着工程と、
複数の補強繊維を所定方向に引き揃えてシート状に形成された補強繊維シート材及び前記布地を当接させて、前記布地の溶融温度より低い温度で加熱して仮接着された前記接着用熱可塑性樹脂材を溶融させることで前記補強繊維シート材及び前記布地を付着させる付着工程と、
を含む熱可塑性樹脂補強シート材の製造方法。 - 前記仮接着工程では、前記接着用熱可塑性樹脂材を前記布地の単位面積当たり1g/m2〜10g/m2付着させる請求項8に記載の熱可塑性樹脂補強シート材の製造方法。
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KR1020147036730A KR101688717B1 (ko) | 2013-11-15 | 2014-07-01 | 열가소성 수지 보강 시트재 및 그의 제조 방법 |
EP14820724.4A EP2899018B1 (en) | 2013-11-15 | 2014-07-01 | Thermoplastic resin reinforcing sheet material and manufacturing process therefor |
CN201480001735.4A CN104781069B (zh) | 2013-11-15 | 2014-07-01 | 热塑性树脂增强片材及其制造方法 |
PCT/JP2014/067492 WO2015072172A1 (ja) | 2013-11-15 | 2014-07-01 | 熱可塑性樹脂補強シート材及びその製造方法 |
US14/414,130 US20160279897A1 (en) | 2013-11-15 | 2014-07-01 | Thermoplastic resin reinforced sheet material and method for manufacturing same |
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WO2021095623A1 (ja) | 2019-11-11 | 2021-05-20 | 東レ株式会社 | 炭素繊維テープ材料、ならびにそれを用いた強化繊維積層体および成形体 |
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WO2016058873A1 (de) * | 2014-10-18 | 2016-04-21 | Oerlikon Textile Gmbh & Co. Kg | Verfahren und vorrichtung zur herstellung eines multifilen fadens aus einer polyamidschmelze |
KR101905555B1 (ko) | 2015-12-16 | 2018-11-21 | 현대자동차 주식회사 | 열가소성 수지 복합재 및 이의 제조방법 |
CN115413862A (zh) * | 2016-11-09 | 2022-12-02 | 耐克创新有限合伙公司 | 针织纺织品和鞋面及其制作方法 |
RU178830U1 (ru) * | 2017-07-27 | 2018-04-19 | Акционерное общество "Препрег-Современные Композиционные Материалы" (АО "Препрег-СКМ") | Мультиаксиальная ткань |
KR102402639B1 (ko) | 2017-11-24 | 2022-05-26 | 삼성전자주식회사 | 전자 장치 및 그의 통신 방법 |
JP7118149B2 (ja) * | 2018-07-03 | 2022-08-15 | フクビ化学工業株式会社 | 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 |
US20220212426A1 (en) * | 2019-05-23 | 2022-07-07 | Toray Industries, Inc. | Fiber-reinforced resin substrate, integrated molded article, and method for manufacturing fiber-reinforced resin substrate |
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WO2021095623A1 (ja) | 2019-11-11 | 2021-05-20 | 東レ株式会社 | 炭素繊維テープ材料、ならびにそれを用いた強化繊維積層体および成形体 |
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EP2899018B1 (en) | 2017-08-30 |
EP2899018A4 (en) | 2016-02-17 |
KR20150073884A (ko) | 2015-07-01 |
KR101688717B1 (ko) | 2016-12-21 |
WO2015072172A1 (ja) | 2015-05-21 |
JP5994060B2 (ja) | 2016-09-21 |
TW201524764A (zh) | 2015-07-01 |
EP2899018A1 (en) | 2015-07-29 |
CN104781069A (zh) | 2015-07-15 |
TWI532594B (zh) | 2016-05-11 |
CN104781069B (zh) | 2016-11-09 |
US20160279897A1 (en) | 2016-09-29 |
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