JP5644496B2 - Fiber reinforced thermoplastic resin molding - Google Patents
Fiber reinforced thermoplastic resin molding Download PDFInfo
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- JP5644496B2 JP5644496B2 JP2010513069A JP2010513069A JP5644496B2 JP 5644496 B2 JP5644496 B2 JP 5644496B2 JP 2010513069 A JP2010513069 A JP 2010513069A JP 2010513069 A JP2010513069 A JP 2010513069A JP 5644496 B2 JP5644496 B2 JP 5644496B2
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- reinforced thermoplastic
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- thermoplastic resin
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- composite material
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- 239000000835 fiber Substances 0.000 title claims description 58
- 229920005992 thermoplastic resin Polymers 0.000 title claims description 56
- 238000000465 moulding Methods 0.000 title claims description 24
- 239000002131 composite material Substances 0.000 claims description 51
- 239000012783 reinforcing fiber Substances 0.000 claims description 32
- 239000011199 continuous fiber reinforced thermoplastic Substances 0.000 claims description 29
- 229920001169 thermoplastic Polymers 0.000 claims description 23
- 239000004416 thermosoftening plastic Substances 0.000 claims description 23
- 239000004744 fabric Substances 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 7
- 238000005520 cutting process Methods 0.000 claims description 6
- 238000010030 laminating Methods 0.000 claims description 2
- 229920005989 resin Polymers 0.000 description 22
- 239000011347 resin Substances 0.000 description 22
- 239000000463 material Substances 0.000 description 15
- 238000000034 method Methods 0.000 description 12
- -1 polyethylenes Polymers 0.000 description 12
- 239000003365 glass fiber Substances 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 239000002759 woven fabric Substances 0.000 description 10
- 239000004743 Polypropylene Substances 0.000 description 7
- 229920001155 polypropylene Polymers 0.000 description 7
- 230000003014 reinforcing effect Effects 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229920002292 Nylon 6 Polymers 0.000 description 3
- 230000005674 electromagnetic induction Effects 0.000 description 3
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- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229920005672 polyolefin resin Polymers 0.000 description 3
- 238000010298 pulverizing process Methods 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 229920002302 Nylon 6,6 Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920006122 polyamide resin Polymers 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 239000012779 reinforcing material Substances 0.000 description 2
- 101000576320 Homo sapiens Max-binding protein MNT Proteins 0.000 description 1
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- 229920000571 Nylon 11 Polymers 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- 229920000007 Nylon MXD6 Polymers 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000006087 Silane Coupling Agent Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000003733 fiber-reinforced composite Substances 0.000 description 1
- 238000009730 filament winding Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000009787 hand lay-up Methods 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003253 poly(benzobisoxazole) Polymers 0.000 description 1
- 229920001643 poly(ether ketone) Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920000417 polynaphthalene Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005464 sample preparation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000012756 surface treatment agent Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 229920006230 thermoplastic polyester resin Polymers 0.000 description 1
- 238000001721 transfer moulding Methods 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- 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
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/50—Removing moulded 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
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- 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
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
-
- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
- B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
- B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
-
- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72141—Fibres of continuous length
-
- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72143—Fibres of discontinuous lengths
-
- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
Description
本発明は、２つの部材を一体化した繊維強化熱可塑性樹脂成形体に関する。さらに詳しくは、該成形体片面が連続繊維強化熱可塑性複合材料からなる部材と該成形体反対面が非連続繊維強化熱可塑性複合材料からなる部材が一体化した成形体を形成していることで、軽量で機械的強度が優れ、複雑な形状の成形が可能となり、生産性も極めて優れ、かつ該成形体全体が熱可塑性樹脂のため再生利用が可能である繊維強化熱可塑性樹脂成形体に関するものである。特に自動車部材、パソコン等の筐体、ロボット部材等に適するものである。 The present invention relates to a fiber-reinforced thermoplastic resin molded body in which two members are integrated. More specifically, by forming a molded body in which a member made of a continuous fiber reinforced thermoplastic composite material on one side of the molded body and a member made of a non-continuous fiber reinforced thermoplastic composite material are integrated on one surface of the molded body. , A fiber reinforced thermoplastic resin molded article that is lightweight, has excellent mechanical strength, can be molded into complex shapes, has extremely high productivity, and can be recycled because the entire molded article is a thermoplastic resin It is. It is particularly suitable for automobile members, housings for personal computers, robot members, and the like.
連続繊維で強化された繊維強化樹脂としては熱硬化性樹脂による繊維強化樹脂（ＦＲＰ）が航空機、鉄道車両、自動車などの輸送機器用途やテニスラケット、ゴルフシャフト、釣り竿等の用途で軽量化と力学特性が要求される構造材として広く使用されている。しかしながら、これらのＦＲＰ部品の中で比較的単純な形状であるゴルフシャフトや釣り竿、ロールやパイプ等では、比較的生産性の高いフィラメントワインデング法やシートワインデング法で製造出来るが、複雑な形状を有するＦＲＰ製品は、多くがオートクレーブ成形やレジントランスファーモールデング（ＲＴＭ）成形法およびハンドレイアップ成形法で製造されることが多く、成形品を大量生産するには生産性が極めて低いという問題点がある。
そのためＦＲＰと非連続繊維強化熱可塑性複合材を張り合わせて一体化することにより、複雑形状を持つ成形品の成形性と生産性を高めることが提案されている。
Therefore, it has been proposed that FRP and a discontinuous fiber reinforced thermoplastic composite material are laminated and integrated to enhance the moldability and productivity of a molded product having a complicated shape.
一方、繊維強化した熱可塑性樹脂シート材料を用いたスタンピング成形は、ＦＲＰと比較して成形サイクルが短く、成形性が優れている。また、成形品は粉砕、溶融することにより再使用が可能であり、環境保護という観点から望ましい材料である。しかしながら、スワール状連続繊維や不連続繊維からなる不織布マットなどに熱可塑性樹脂を含浸した繊維強化熱可塑性樹脂シート材料をスタンピング成形した成形品は強化繊維の含有率を大きくすることが困難なため、強度や剛性等の機械的特性が比較的低い。特に、寸法の高いリブや肉厚の薄いリブ等を有する複雑な形状の成形品では、強化繊維の含有率が低い上に、強化繊維同志が絡んでいるため、樹脂と強化繊維が分離して流動する傾向があり、強度が更に低下し、成形品の機械的特性が場所によってばらつくという問題点がある。また、織物を強化繊維として用いた繊維強化熱可塑性樹脂シート材料から得られる成形品は強度や弾性率等は良好であるが、複雑な形状を有する成形品、特にリブやボス等の突起物を有する成形品は連続繊維では形状に追従できず、不十分な成形品しか得られないという問題点があった。 On the other hand, stamping molding using a fiber reinforced thermoplastic resin sheet material has a shorter molding cycle and excellent moldability as compared with FRP. In addition, the molded product can be reused by pulverization and melting, and is a desirable material from the viewpoint of environmental protection. However, a molded product obtained by stamping a fiber reinforced thermoplastic resin sheet material impregnated with a thermoplastic resin into a non-woven mat made of swirl continuous fibers or discontinuous fibers is difficult to increase the content of reinforcing fibers. Mechanical properties such as strength and rigidity are relatively low. In particular, in a molded product with a complicated shape having ribs with high dimensions or thin ribs, the reinforcing fiber content is low and the reinforcing fibers are entangled, so the resin and the reinforcing fibers are separated. There is a tendency to flow, the strength further decreases, and the mechanical properties of the molded product vary from place to place. In addition, a molded product obtained from a fiber reinforced thermoplastic resin sheet material using a woven fabric as a reinforcing fiber has good strength and elastic modulus. However, a molded product having a complicated shape, particularly protrusions such as ribs and bosses. There is a problem in that the formed product cannot follow the shape with continuous fibers, and only an insufficiently formed product can be obtained.
連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料を一体化した繊維強化熱可塑性樹脂成形体で、機械的特性に優れ、リブやボス等の突起物を有する複雑形状の成形品においても、成形性が優れ、品質の安定した、生産性に優れた繊維強化熱可塑性樹脂成形体を提供することを課題とするものである。 A fiber reinforced thermoplastic resin molded product that integrates a continuous fiber reinforced thermoplastic composite and a non-continuous fiber reinforced thermoplastic composite, and has excellent mechanical properties and has a complex shape with protrusions such as ribs and bosses. Another object of the present invention is to provide a fiber-reinforced thermoplastic resin molded article having excellent moldability, stable quality, and excellent productivity.
上記課題を解決するために鋭意研究した結果、連続繊維強化熱可塑性複合材料がテープ状プリプレグから得られる織物または多軸積層布からなり、非連続繊維強化熱可塑性複合材料がテープ状プリプレグを所定の長さに切断した短冊状物からなるものを一体成形することにより、上記目的を達成することを見出し、本発明を完成するに至った。 As a result of diligent research to solve the above-mentioned problems, the continuous fiber reinforced thermoplastic composite material is composed of a woven fabric or a multiaxial laminated fabric obtained from a tape-shaped prepreg, and the discontinuous fiber reinforced thermoplastic composite material is formed into a predetermined tape prepreg It has been found that the object can be achieved by integrally forming a strip-shaped product cut into lengths, and the present invention has been completed.
すなわち本発明は、（１）繊維強化熱可塑性樹脂成形体であって、該成形体の片面が連続繊維強化熱可塑性複合材料を含む部材Ａからなり、該成形体の反対面が非連続繊維強化熱可塑性複合材料を含む部材Ｂからなり、部材Ａと部材Ｂが一体化した成形体を形成していることを特徴とする繊維強化熱可塑性樹脂成形体。（２）繊維強化熱可塑性樹脂成形体における非連続繊維強化熱可塑性複合材料からなる部材Ｂには突起物が形成されていることを特徴とする前記（１）記載の繊維強化熱可塑性樹脂成形体。（３）繊維強化熱可塑性樹脂成形体における片面全体が連続繊維強化熱可塑性複合材料からなる部材Ａから形成されていることを特徴とする前記（１）〜（２）のいずれかに記載の繊維強化熱可塑性樹脂成形体。（４）連続繊維強化熱可塑性複合材料がテープ状プリプレグから得られる織物または多軸積層布であることを特徴とする前記（１）〜（３）のいずれかに記載の繊維強化熱可塑性樹脂成形体。（５）非連続繊維強化熱可塑性複合材料が、平均繊維長１０〜６０ｍｍの強化繊維を含有してなることを特徴とする前記（１）〜（４）のいずれかに記載の繊維強化熱可塑性樹脂成形体。（６）繊維強化熱可塑性樹脂成形体における強化繊維の体積含有率が２０％〜６０％であることを特徴とする前記（１）〜（５）のいずれかに記載の繊維強化熱可塑性樹脂成形体。（７）繊維強化熱可塑性樹脂成形体の部材Ｂ側に形成される突起物の高さは３ｍｍ以上であり、かつ強化繊維が均一に分散されていることを特徴とする前記（１）〜（６）のいずれかに記載の繊維強化熱可塑性樹脂成形体。 That is, the present invention is (1) a fiber reinforced thermoplastic resin molded body, wherein one side of the molded body is composed of a member A containing a continuous fiber reinforced thermoplastic composite material, and the opposite surface of the molded body is a discontinuous fiber reinforced material. A fiber-reinforced thermoplastic resin molded body comprising a member B containing a thermoplastic composite material, wherein a molded body in which the members A and B are integrated is formed. (2) The fiber-reinforced thermoplastic resin molded article according to (1) above, wherein protrusions are formed on the member B made of the discontinuous fiber-reinforced thermoplastic composite material in the fiber-reinforced thermoplastic resin molded article. . (3) The fiber according to any one of (1) to (2), wherein the entire surface of one side of the fiber-reinforced thermoplastic resin molded body is formed from a member A made of a continuous fiber-reinforced thermoplastic composite material. Reinforced thermoplastic resin molding. (4) The fiber reinforced thermoplastic resin molding according to any one of (1) to (3), wherein the continuous fiber reinforced thermoplastic composite material is a woven fabric or a multiaxial laminated fabric obtained from a tape-shaped prepreg. body. (5) The fiber-reinforced thermoplastic as described in any one of (1) to (4) above, wherein the discontinuous fiber-reinforced thermoplastic composite material contains reinforcing fibers having an average fiber length of 10 to 60 mm. Resin molded body. (6) The fiber-reinforced thermoplastic resin molding as described in any one of (1) to (5) above, wherein the volume content of the reinforcing fiber in the fiber-reinforced thermoplastic resin molding is 20% to 60%. body. (7) The heights of the protrusions formed on the member B side of the fiber-reinforced thermoplastic resin molded body are 3 mm or more, and the reinforcing fibers are uniformly dispersed, (1) to ( The fiber-reinforced thermoplastic resin molded article according to any one of 6).
本発明における繊維強化熱可塑性樹脂成形体は、連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料を一体化して成形することによって、優れた機械的特性を有し、かつ、突起物がある複雑な形状の成形品を一体成形で得られる。また、成形サイクルが短く、生産性が優れているので大量生産が可能である。また、成形品は粉砕、再溶融することにより再使用が可能であり、環境保護という観点からも望ましい材料である。よって、本発明による繊維強化熱可塑性樹脂成形体は、機械的強度や生産性が要求され、複雑な形状を有する自動車部材、パソコン等の筐体、ロボット部材等の幅広い分野で使用することができる。従って産業界に寄与すること大である。 The fiber-reinforced thermoplastic resin molded article according to the present invention has excellent mechanical properties by integrally molding a continuous fiber-reinforced thermoplastic composite material and a discontinuous fiber-reinforced thermoplastic composite material, and a protrusion. A molded product having a complicated shape can be obtained by integral molding. Further, since the molding cycle is short and the productivity is excellent, mass production is possible. Further, the molded product can be reused by pulverization and remelting, which is a desirable material from the viewpoint of environmental protection. Therefore, the fiber reinforced thermoplastic resin molded article according to the present invention is required to have mechanical strength and productivity, and can be used in a wide range of fields such as automobile parts having a complicated shape, housings for personal computers, robot parts, and the like. . Therefore, it is important to contribute to the industry.
以下、本発明を具体的に説明する。本発明における連続繊維強化熱可塑性複合材料および非連続繊維強化熱可塑性複合材料は、いずれもテープ状プリプレグをベースに作られている。テープ状プリプレグは強化用の連続繊維束に熱可塑性樹脂を含浸したものである。連続繊維束は無撚で、フィラメント数は１６００本〜６００００本、より好ましくは１６００〜２４０００本である。またフィラメントの直径は３〜３０μｍ、より好ましくは６〜２０μｍであるが、特にこの範囲に限定されるものではない。テープ状プリプレグの形状は特に限定されるものではなく、連続繊維強化熱可塑性複合材料や非連続繊維強化熱可塑性複合材料の必要とする特性によって使い分けることが出来る。 Hereinafter, the present invention will be specifically described. The continuous fiber reinforced thermoplastic composite material and the discontinuous fiber reinforced thermoplastic composite material in the present invention are both made based on a tape-shaped prepreg. The tape-shaped prepreg is obtained by impregnating a continuous fiber bundle for reinforcement with a thermoplastic resin. The continuous fiber bundle is untwisted, and the number of filaments is 1600 to 60000, more preferably 1600 to 24000. The filament has a diameter of 3 to 30 μm, more preferably 6 to 20 μm, but is not particularly limited to this range. The shape of the tape-shaped prepreg is not particularly limited, and can be properly used depending on the properties required for the continuous fiber reinforced thermoplastic composite material and the discontinuous fiber reinforced thermoplastic composite material.
テープ状プリプレグの製造方法は特に限定されるものではないが、例えば押出機の先端にクロスヘッドダイを取り付け、連続繊維束に溶融樹脂を含浸させる方式などがあり、特にテープ形状を一定に保って、樹脂の含浸性を向上させるために加圧賦形ロールを用いることが好ましい。連続繊維束の開繊率と樹脂の溶融粘度および加圧賦形ロールの加圧条件等によってテープ状プリプレグの強化繊維の含有率や空隙率が決定される。そのためテープ状プリプレグの形状は強化繊維の含有率や空隙率と関連する場合が多い。 The method for producing the tape-shaped prepreg is not particularly limited. For example, there is a method in which a crosshead die is attached to the tip of an extruder and a continuous fiber bundle is impregnated with a molten resin. In order to improve the impregnation property of the resin, it is preferable to use a pressure shaping roll. The content of the reinforcing fibers and the porosity of the tape-shaped prepreg are determined depending on the fiber opening rate of the continuous fiber bundle, the melt viscosity of the resin, and the pressurizing conditions of the pressurizing roll. For this reason, the shape of the tape-shaped prepreg is often related to the content of the reinforcing fibers and the porosity.
テープ状プリプレグの空隙率は極めて重要であり、高い空隙率のテープ状プリプレグを使用すると製品の成形過程において完全に含浸することが出来ず、成形品にボイドが残り機械的強度が低下し好ましくない。従って、テープ状プリプレグの空隙率は８％以下が必要であり、好ましくは５％以下である。このテープ状プリプレグの空隙率とはテープ状プリプレグを長さ１０ｍｍに切断し、それを２ｇ程度集め、水に浸漬後の重量増加分を元のテープ状プリプレグの重量で除した値である。この測定では水に界面活性剤を少量加えるとテープ状プリプレグが水に浸漬しやすくなる。当然のことながら、秤量の時には表面の水分を充分拭いて除去することが必要である。 The porosity of the tape-shaped prepreg is extremely important. If a tape-shaped prepreg with a high porosity is used, it cannot be completely impregnated during the molding process of the product, and voids remain in the molded product, which is undesirable. . Therefore, the porosity of the tape-shaped prepreg needs to be 8% or less, and preferably 5% or less. The porosity of the tape-shaped prepreg is a value obtained by cutting the tape-shaped prepreg to a length of 10 mm, collecting about 2 g of the prepreg, and dividing the weight increase after being immersed in water by the weight of the original tape-shaped prepreg. In this measurement, when a small amount of a surfactant is added to water, the tape-shaped prepreg is easily immersed in water. As a matter of course, it is necessary to sufficiently wipe off the water on the surface when weighing.
テープ状プリプレグの強化繊維の体積含有率Ｖｆは、２０％〜６０％が好ましい。更に好ましくは、３０％〜６０％である。強化繊維の体積含有率Ｖｆが２０％以下の場合には成形体の強化効率が低く好ましくない。また 強化繊維の体積含有率Ｖｆが６０％以上になるとテープ状プリプレグの製造工程で空隙率が高くなり、成形品にボイドが残り、成形品の機械的強度が低下するため、好ましくない。 The volume content Vf of the reinforcing fiber of the tape-shaped prepreg is preferably 20% to 60%. More preferably, it is 30% to 60%. When the volume content Vf of the reinforcing fiber is 20% or less, the reinforcing efficiency of the molded body is low, which is not preferable. On the other hand, if the volume content Vf of the reinforcing fiber is 60% or more, the void ratio is increased in the production process of the tape-shaped prepreg, voids remain in the molded product, and the mechanical strength of the molded product is lowered.
本発明のテープ状プリプレグに用いられる強化繊維としては、ガラス繊維、炭素繊維、アラミド繊維、ＰＢＯ繊維、セラミックス繊維、金属繊維等の連続繊維が挙げられるが、これらに限定されるものではない。また、これらの繊維を２種類以上併用しても良い。これらの強化繊維は熱可塑性樹脂との接着性を良くするために、表面処理がなされているものが好ましい。例えば ガラス繊維ではマトリックスとなる熱可塑性樹脂との反応基を持つシランカップリング剤で表面処理するとガラス繊維強化熱可塑性樹脂複合材料の機械的強度が大きく向上することが知られている。これらの強化繊維の中でも、ガラス繊維、炭素繊維は、表面処理剤の最適化が容易であり、樹脂との接着性が良好であることから好ましい。 Examples of the reinforcing fibers used in the tape-shaped prepreg of the present invention include, but are not limited to, continuous fibers such as glass fibers, carbon fibers, aramid fibers, PBO fibers, ceramic fibers, and metal fibers. Two or more of these fibers may be used in combination. These reinforcing fibers are preferably subjected to a surface treatment in order to improve the adhesiveness with the thermoplastic resin. For example, it is known that the mechanical strength of a glass fiber reinforced thermoplastic resin composite material is greatly improved when glass fiber is surface-treated with a silane coupling agent having a reactive group with a thermoplastic resin as a matrix. Among these reinforcing fibers, glass fibers and carbon fibers are preferable because the surface treatment agent can be easily optimized and the adhesiveness to the resin is good.
本発明のテープ状プリプレグに用いられる熱可塑性樹脂としては各種ポリエチレン、ポリプロピレンおよびその共重合体や変性体を含むポリオレフィン系樹脂、ナイロン６、ナイロン６６、ナイロン１１、ナイロン１２、ＭＸＤ６等を含むポリアミド系樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリナフタレンテレフタレート等を含む熱可塑性ポリエステル系樹脂、ポリカーボネート、ポリエーテルイミド、ポリフェニレンサルファイド、ポリエーテルケトンおよび各種の熱可塑性エラストマー等を挙げる事ができるが、これらに限定されるものではない。また、２種類以上の熱可塑性樹脂を併用することが出来る。熱可塑性樹脂の中でも、ポリオレフィン系樹脂、ポリアミド系樹脂は、耐衝撃性、耐溶剤性、耐摩耗性、耐油性等に優れ、コスト的にも他の熱可塑性樹脂に比べて有利であるため、特に好ましい。ポリオレフィン系樹脂の代表であるポリプロピレンは、成形性にも優れており、非常に扱いやすい樹脂であるが、その反面、強化繊維との接着性に乏しいことが欠点として挙げられていたが、近年、酸変性することにより接着性が改良されることが知られている。そのため、本発明の繊維強化熱可塑性複合材料を構成する樹脂にポリプロピレンを用いる場合は、このような酸変性がなされていることが好ましい。また、必要に応じて他の添加剤を配合することも出来る。 Examples of the thermoplastic resin used in the tape-shaped prepreg of the present invention include polyolefin resins including various polyethylenes, polypropylenes, copolymers and modified products thereof, and polyamide resins including nylon 6, nylon 66, nylon 11, nylon 12, MXD6, and the like. Resins, thermoplastic polyester resins including polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, etc., polycarbonate, polyether imide, polyphenylene sulfide, polyether ketone and various thermoplastic elastomers can be mentioned, but are not limited to these Is not to be done. Two or more types of thermoplastic resins can be used in combination. Among thermoplastic resins, polyolefin resins and polyamide resins are excellent in impact resistance, solvent resistance, abrasion resistance, oil resistance, etc., and are advantageous compared to other thermoplastic resins in terms of cost. Particularly preferred. Polypropylene, which is a representative polyolefin-based resin, is excellent in moldability and is very easy to handle, but on the other hand, it has been mentioned as a disadvantage that it has poor adhesion to reinforcing fibers. It is known that adhesion is improved by acid modification. Therefore, when polypropylene is used as the resin constituting the fiber-reinforced thermoplastic composite material of the present invention, it is preferable that such acid modification is performed. Moreover, another additive can also be mix | blended as needed.
本発明のテープ状プリプレグに用いられる熱可塑性樹脂はテープ状プリプレグを製造する時に各熱可塑性樹脂に適する耐熱安定剤、酸化防止剤、紫外線吸収剤、光安定剤、帯電防止剤、変性剤等を必要に応じて添加することができる。また、本発明の目的を損なわない範囲で、他の樹脂や充填剤等を添加できる。 The thermoplastic resin used in the tape-shaped prepreg of the present invention includes a heat stabilizer, antioxidant, ultraviolet absorber, light stabilizer, antistatic agent, modifier, etc. suitable for each thermoplastic resin when producing the tape-shaped prepreg. It can be added as necessary. Further, other resins, fillers, and the like can be added as long as the object of the present invention is not impaired.
本発明のテープ状プリプレグは繊維強化熱可塑性樹脂成形体の中間体であるが、高い強化繊維の含有率を有し、かつ空隙率が低い。この優れたテープ状プリプレグを用いて作製されたシート状材料は、その後の成形工程において低い成形圧力で容易に高強度、高弾性率を持つ優れた繊維強化熱可塑性樹脂成形体を得ることが出来る。 The tape-shaped prepreg of the present invention is an intermediate of a fiber-reinforced thermoplastic resin molded article, but has a high content of reinforcing fibers and a low porosity. The sheet-like material produced using this excellent tape-shaped prepreg can easily obtain an excellent fiber-reinforced thermoplastic resin molded article having high strength and high elastic modulus at a low molding pressure in the subsequent molding process. .
本発明における連続繊維強化熱可塑性複合材料は、テープ状プリプレグ材料を用いて作られている。テープ状プリプレグは既に、強化繊維に熱可塑性樹脂が含浸しているので、連続繊維強化熱可塑性複合材料はこのテープ状プリプレグの配列方法と成形する製品寸法に合わせて、裁断および配置をすることで得ることができる。
テープ状プリプレグは強化繊維が一軸方向に配列しているので、テープ状プリプレグの配置方向は極めて重要である。本発明における連続繊維強化熱可塑性複合材料はテープ状プリプレグから得られる織物または多軸積層布によって構成される。織物とはテープ状プリプレグを縦、横に織り込んだもので、強化繊維の方向が縦と横方向に配列している。
一方、多軸積層布とはテープ状プリプレグが縦、横以外に、例えば縦方向に対して４５度傾いた方向にテープ状プリプレグを配列したものである。この多軸積層布は、成形する製品で最も強度が必要とする方向にテープ状プリプレグを配列することが出来るので、強化繊維の補強効率が最もすぐれた強化形態である。また、原理的には３６０度、全方向に強化繊維を配列した多軸積層布を製作することが可能である。The continuous fiber reinforced thermoplastic composite material in the present invention is made using a tape-shaped prepreg material. Since the tape-shaped prepreg is already impregnated with thermoplastic resin in the reinforcing fiber, the continuous fiber-reinforced thermoplastic composite material can be cut and arranged according to the method of arranging this tape-shaped prepreg and the size of the product to be molded. Can be obtained.
Since the reinforcing fibers are arranged in a uniaxial direction in the tape-shaped prepreg, the arrangement direction of the tape-shaped prepreg is extremely important. The continuous fiber reinforced thermoplastic composite material in the present invention is constituted by a woven fabric or a multiaxial laminated fabric obtained from a tape-shaped prepreg. A woven fabric is a tape-like prepreg woven in the vertical and horizontal directions, and the directions of the reinforcing fibers are arranged in the vertical and horizontal directions.
On the other hand, the multiaxial laminated fabric is one in which the tape-shaped prepreg is arranged in a direction inclined by 45 degrees with respect to the vertical direction in addition to the vertical and horizontal directions. This multiaxial laminated fabric is a reinforcing form in which the reinforcing efficiency of reinforcing fibers is the best because the tape-shaped prepreg can be arranged in the direction where the strength is most required in the product to be molded. In principle, it is possible to manufacture a multiaxial laminated fabric in which reinforcing fibers are arranged in all directions at 360 degrees.
テープ状プリプレグから作られる連続繊維強化熱可塑性複合材料の中で、織物はテープ状プリプレグが織り込まれているため、成形する寸法に裁断してもテープ状プリプレグがバラけて形状が崩れることはない。一方、多軸積層布は成形する寸法に裁断するとテープ状プリプレグの一部がバラけてしまう。そのため多軸積層布を作製した後、テープ状プリプレグを何らかの方法で仮止めを行い、一体化することが必要である。仮止め方法としては超音波発信機を用いたスポット溶着やスティッチングを施すことにより、テープ状プリプレグのバラけを防止することが出来る。また、テープ状プリプレグを仮止めを行い、一体化することにより成形サイクルを短縮することが出来ると共に、最終成形品の強度バラツキが減少し、成形品の品質を均一なものとすることが出来る。 Among the continuous fiber reinforced thermoplastic composites made from tape-shaped prepregs, the fabric is woven with tape-shaped prepregs, so the tape-shaped prepreg will not break up and lose its shape even if cut into the dimensions to be molded. . On the other hand, when the multiaxial laminated fabric is cut to the size to be molded, a part of the tape-shaped prepreg is scattered. Therefore, after producing a multiaxial laminated fabric, it is necessary to temporarily fix the tape-shaped prepreg by some method and to integrate them. As a temporary fixing method, spot welding or stitching using an ultrasonic transmitter can be performed to prevent the tape-shaped prepreg from being scattered. Further, by temporarily fixing and integrating the tape-shaped prepreg, the molding cycle can be shortened, the strength variation of the final molded product is reduced, and the quality of the molded product can be made uniform.
本発明における非連続繊維強化熱可塑性複合材料はテープ状プリプレグを所定の長さに切断した短冊状のプリプレグの薄片をランダムな方向に分散、堆積したものを加熱、成形することによって得られる。
テープ状プリプレグの切断する長さは１０ｍｍ〜６０ｍｍであり、好ましくは２０ｍｍ〜５０ｍｍである。強化繊維はテープ状プリプレグの長さ方向に配列されているため、短冊状に切断されたテープ状プリプレグの長さが強化繊維の長さとほぼ等しくなる。
切断する長さが１０ｍｍ以下では強化繊維の補強効率が低く好ましくない。一方、切断する長さが６０ｍｍ以上では成形品のリブやボス等の突起物に強化繊維が均一に流入することが困難になる場合が多い。特にリブ等の先端が１〜２ｍｍと薄い場合や５０ｍｍ以上の長いリブやボスを持つ成形品においては、繊維の流入が少なくなり、リブ先端部の補強効果が低下する場合があり好ましくない。
本発明の非連続繊維強化熱可塑性複合材料では成形品の突起物の形状、大きさおよび高さ等の形状によって、２種類以上の長さの短冊状テープ状プリプレグを使用することも出来る。The discontinuous fiber reinforced thermoplastic composite material in the present invention can be obtained by heating and molding a strip-shaped prepreg slice obtained by cutting a tape-shaped prepreg into a predetermined length and dispersing and depositing them in a random direction.
The length of the tape-shaped prepreg to be cut is 10 mm to 60 mm, preferably 20 mm to 50 mm. Since the reinforcing fibers are arranged in the length direction of the tape-shaped prepreg, the length of the tape-shaped prepreg cut into strips is substantially equal to the length of the reinforcing fibers.
If the length to be cut is 10 mm or less, the reinforcing efficiency of the reinforcing fiber is low, which is not preferable. On the other hand, when the length to be cut is 60 mm or more, it is often difficult for the reinforcing fibers to uniformly flow into protrusions such as ribs and bosses of the molded product. In particular, when the tip of the rib or the like is as thin as 1 to 2 mm, or in a molded product having a long rib or boss of 50 mm or more, the inflow of fibers is reduced, and the reinforcing effect of the tip of the rib may be lowered, which is not preferable.
In the discontinuous fiber reinforced thermoplastic composite material of the present invention, two or more kinds of strip-like tape-shaped prepregs can be used depending on the shape, size, height, etc. of the projections of the molded product.
本発明の繊維強化熱可塑性樹脂成形体に形成される突起物とは、成形体表面より突起しているものである。具体的な例としてはリブ、ボス、直方体や立方体などがあげられるが、それらに限定されるものではなく、複雑な形状も含まれる。 The protrusions formed on the fiber-reinforced thermoplastic resin molded body of the present invention are those that protrude from the surface of the molded body. Specific examples include ribs, bosses, rectangular parallelepipeds, cubes, and the like, but are not limited to these and include complex shapes.
本発明の繊維強化熱可塑性樹脂成形体から得られる成形品は、片面に３ｍｍ以上の高さを持つ突起物を有する複雑な成形品で、かつ該成形品には高い強度、弾性率やタフネス等が要求される成形品を製造するのに適するものである。そのため連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料を組み合わせることによって、複雑な形状を有する製品形状と高い力学的な要求特性を満たす成形品の製造が可能となる。
本発明の製造法は特に限定されるものではないが、次のような工程で成形品の製造を行うことが出来る。テープ状プリプレグを所定に長さに切断した短冊状の薄片を、リブやボス等の突起物を形成する金型の下型にランダムな向きに配列させてチャージする。特にリブやボスの大きさや深さによって、テープ状プリプレグの切断した短冊状の長さや下型にチャージするプリプレグの量等を調節する必要がある。
次に、その上にテープ状プリプレグから得られた織物または多軸積層布を少なくとも１層積層した後、上型を閉じ、電磁誘導加熱によって熱可塑性樹脂の融点より高い温度まで加熱し、所定の圧力下で保持した後、冷却水により金型を冷却することにより成形品を取り出すことが出来る。
本発明において製造法は特に限定されるものではないが、電磁誘導加熱によってチャージしたプリプレグを加熱溶融する方式は、金型に材料をチャージする際の材料の取り扱いのし易さ等で好ましい製造方法である。勿論、連続繊維強化および非連続繊維強化の複合材料をそれぞれ、あらかじめシート状材料にしておき、別々に加熱溶融することにより、従来のスタンピング成形により、一体成形することもできる。The molded product obtained from the fiber-reinforced thermoplastic resin molded article of the present invention is a complex molded product having a projection having a height of 3 mm or more on one side, and the molded product has high strength, elastic modulus, toughness, etc. It is suitable for manufacturing a molded product that is required. Therefore, by combining a continuous fiber reinforced thermoplastic composite material and a non-continuous fiber reinforced thermoplastic composite material, it becomes possible to manufacture a product having a complex shape and a molded product satisfying high mechanical requirements.
Although the manufacturing method of this invention is not specifically limited, A molded article can be manufactured in the following processes. A strip-shaped thin piece obtained by cutting a tape-shaped prepreg to a predetermined length is charged by being arranged in a random direction on a lower mold of a mold for forming protrusions such as ribs and bosses. In particular, it is necessary to adjust the length of the strip-shaped strip of the tape-shaped prepreg, the amount of prepreg charged in the lower mold, and the like depending on the size and depth of the ribs and bosses.
Next, after laminating at least one layer of the woven fabric or multiaxial laminated fabric obtained from the tape-shaped prepreg, the upper die is closed and heated to a temperature higher than the melting point of the thermoplastic resin by electromagnetic induction heating. After being held under pressure, the molded product can be taken out by cooling the mold with cooling water.
In the present invention, the production method is not particularly limited, but the method of heating and melting the prepreg charged by electromagnetic induction heating is preferable because of the ease of handling of the material when charging the material to the mold. It is. Of course, the continuous fiber reinforced and non-continuous fiber reinforced composite materials can be formed into a sheet-like material in advance, and separately heated and melted, so that they can be integrally formed by conventional stamping molding.
本発明の繊維強化熱可塑性樹脂成形体は連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料を組み合わせて製造されるが、連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料の熱可塑性樹脂が同じ樹脂から出来ていることが最も好ましいが、必ずしも同一樹脂に限定されるものではない。異なった樹脂の組み合わせでも、樹脂同士が相容性を有し、溶融接合が可能であれば使用することが出来る。例えば、ポリプロピレンとポリエチレン、ナイロン６とナイロン６６、ＰＥＴとＰＢＴ等の同種類樹脂の組み合わせである。一方、マレイン酸変性ポリプロピレンとナイロン６の組み合わせのように、金型内で溶融圧縮している僅かな時間で反応が進み、一体化するような樹脂の組み合わせであれば異種の熱可塑性樹脂を使用することも出来る。 The fiber reinforced thermoplastic resin molding of the present invention is produced by combining a continuous fiber reinforced thermoplastic composite material and a non-continuous fiber reinforced thermoplastic composite material, but a continuous fiber reinforced thermoplastic composite material and a non-continuous fiber reinforced thermoplastic composite material. Most preferably, the thermoplastic resin is made of the same resin, but is not necessarily limited to the same resin. Even combinations of different resins can be used if the resins are compatible and can be melt bonded. For example, a combination of the same kind of resin such as polypropylene and polyethylene, nylon 6 and nylon 66, and PET and PBT. On the other hand, different combinations of thermoplastic resins can be used as long as the reaction proceeds in a short period of time during melt compression in the mold, such as a combination of maleic acid-modified polypropylene and nylon 6. You can also
以下に実施例により本発明をさらに詳細に説明するが、本発明はこれらの実施例により何ら制限されるものではない。
また以下に実施例、比較例において示した試料や物性値は、下記のような試料の作製法や試験法で行った。
・連続繊維強化熱可塑性複合材料はガラス繊維を強化材とし、熱可塑性樹脂にマレイン酸変性ポリプロピレンを使用し、体積含有率Ｖｆが５０％のテープ状プリプレグを用い、多軸積層布を作製した。
・非連続繊維強化熱可塑性複合材料はガラス繊維を強化材とし、熱可塑性樹脂にマレイン酸変性ポリプロピレンを使用し、体積含有率Ｖｆが５０％のテープ状プリプレグを用い、３０ｍｍの長さに切断した短冊状のプリプレグを使用した。
・成形品は図１に示した「リブ付き平板」の金型を使用し、上記の連続繊維強化熱可塑性複合材料および非連続繊維強化熱可塑性複合材料を金型のキャビティーに装入し、上型を閉じて、電磁誘導加熱で約２５０℃に加熱、加圧した後、金型を冷却して成形品を取り出した。
・成形品の曲げ強度は成形品の図１に示したａ、ｂ、ｃ、ｄの各部位から試料を切り出し、ＩＳO１７８に準じて測定した。
・ガラス繊維の体積含有率Ｖｆは図１に示したａ、ｂ、ｃ、ｄの各部位から試料を切り出し、電気炉で６２５℃に加熱し、樹脂成分を完全に除去した後、残ったガラス繊維の重量から計算して測定した。The present invention will be described in more detail with reference to the following examples. However, the present invention is not limited to these examples.
Samples and physical property values shown in the following Examples and Comparative Examples were obtained by the following sample preparation methods and test methods.
A continuous fiber reinforced thermoplastic composite material was made of glass fiber as a reinforcing material, maleic acid-modified polypropylene was used as the thermoplastic resin, and a tape-shaped prepreg having a volume content Vf of 50% was used to produce a multiaxial laminated fabric.
The discontinuous fiber reinforced thermoplastic composite material is made of glass fiber as a reinforcing material, maleic acid-modified polypropylene is used as the thermoplastic resin, and a tape-shaped prepreg having a volume content Vf of 50% is cut into a length of 30 mm. A strip-shaped prepreg was used.
The molded product uses the “ribbed flat plate” mold shown in FIG. 1 and the above continuous fiber reinforced thermoplastic composite material and the discontinuous fiber reinforced thermoplastic composite material are charged into the mold cavity. The upper mold was closed and heated and pressurized to about 250 ° C. by electromagnetic induction heating, and then the mold was cooled and the molded product was taken out.
The bending strength of the molded product was measured in accordance with ISO178 by cutting a sample from each part a, b, c, and d shown in FIG.
The volume content Vf of the glass fiber is obtained by cutting a sample from each of the parts a, b, c, and d shown in FIG. 1 and heating it to 625 ° C. in an electric furnace to completely remove the resin component, and then the remaining glass It was calculated from the weight of the fiber.
実施例１は連続繊維強化熱可塑性複合材料である平織物と非連続繊維強化熱可塑性複合材料である３０ｍｍの長さに切断したテープ状プリプレグからなる成形品である。また、比較例１は連続繊維強化熱可塑性複合材料である平織物のみを使用した成形品であり、比較例２は非連続繊維強化熱可塑性複合材料である３０ｍｍの長さに切断したテープ状プリプレグからなる成形品である。
評価結果は表１に示した。Example 1 is a molded article composed of a plain woven fabric which is a continuous fiber reinforced thermoplastic composite material and a tape-shaped prepreg cut to a length of 30 mm which is a discontinuous fiber reinforced thermoplastic composite material. Comparative Example 1 is a molded product using only a plain fabric that is a continuous fiber reinforced thermoplastic composite material, and Comparative Example 2 is a tape-shaped prepreg that is cut to a length of 30 mm that is a discontinuous fiber reinforced thermoplastic composite material. It is a molded article consisting of
The evaluation results are shown in Table 1.
実施例１では成形品の平板部分は主にテープ状プリプレグで織った織物（平織）からなる成形品であり、そのため平板部分を示すａ部位の強度が極めて高い。一方、リブ部分は主に３０ｍｍの長さに切断されたテープ状プリプレグからなる成形品であり、リブの先端にあたるｄ部位でもカラス繊維の体積含有率Ｖｆが４０％以上あり、リブの先端まで強化繊維が充填されており、強度も高い値を示している。
比較例１では成形品の平板部分は主にテープ状プリプレグで織った織物（平織）のみからなる成形品である。織物の補強効果が高いため、平板部分を示すａ部位の強度は高い。しかしながら、リブ部分に強化繊維が入り込めないため、ｂ部位ではガラス繊維の体積含有率Ｖｆが２０％となり、更にｃ部位やｄ部位ではガラス繊維の体積含有率Ｖｆが０％となり、樹脂のみの強度しか得られなかった。
比較例２では非連続繊維強化熱可塑性複合材料である３０ｍｍの長さに切断されたテープ状プリプレグからなる成形品である。流動性が優れるため、リブ部分にも強化繊維が充填されている。しかしながら、最も強度を必要とするａ部位の平板部分では強度が低く、織物によって補強された成形品に対して著しく見劣りがする。In Example 1, the flat plate portion of the molded product is a molded product mainly made of a woven fabric (plain weave) woven with a tape-shaped prepreg, and therefore the strength of the portion a indicating the flat plate portion is extremely high. On the other hand, the rib part is a molded product mainly composed of a tape-shaped prepreg cut to a length of 30 mm, and the volume content Vf of the crow fiber is 40% or more even at the d part corresponding to the tip of the rib, and it is reinforced to the tip of the rib. The fiber is filled and the strength is high.
In Comparative Example 1, the flat plate portion of the molded product is a molded product mainly composed of a woven fabric (plain weave) woven mainly with a tape-shaped prepreg. Since the reinforcing effect of the woven fabric is high, the strength of the portion a indicating the flat plate portion is high. However, since the reinforcing fiber cannot enter the rib portion, the volume content Vf of the glass fiber is 20% at the b portion, and the volume content Vf of the glass fiber is 0% at the c portion and the d portion. Only strength was obtained.
Comparative Example 2 is a molded article made of a tape-shaped prepreg cut to a length of 30 mm, which is a discontinuous fiber reinforced thermoplastic composite material. Since the fluidity is excellent, the rib portion is also filled with reinforcing fibers. However, the strength of the flat portion of the portion a requiring the highest strength is low, and the molded product reinforced by the fabric is considerably inferior.
本発明における繊維強化熱可塑性樹脂成形体は連続繊維強化熱可塑性複合材料と非連続繊維強化熱可塑性複合材料を一体化して成形することによって優れた機械的特性を有し、かつ、リブやボス等の突起物を有する複雑な形状の成形品を一体成形で成形できる。また、成形サイクルが短く、生産性が優れているので大量生産が可能である。さらにまた、成形品は、粉砕、再溶融することにより再使用が可能であり、環境保護という観点から望ましい材料である。よって、機械的強度や生産性が要求され、複雑な形状を有する自動車部材、航空機部材、二輪車部材、自転車等の輸送機器用途、電子機器やパソコン等の筐体およびロボット部材等の幅広い分野で使用することができる。したがって、産業界に寄与すること大である。 The fiber reinforced thermoplastic resin molded body in the present invention has excellent mechanical properties by integrally molding a continuous fiber reinforced thermoplastic composite material and a discontinuous fiber reinforced thermoplastic composite material, and has ribs, bosses, etc. A molded product having a complicated shape having a plurality of protrusions can be formed by integral molding. Further, since the molding cycle is short and the productivity is excellent, mass production is possible. Furthermore, the molded product can be reused by pulverization and remelting, and is a desirable material from the viewpoint of environmental protection. Therefore, mechanical strength and productivity are required, and it is used in a wide range of fields such as automobile parts, aircraft parts, two-wheeled vehicle parts, bicycles and other transportation equipment applications, housings for electronic devices and personal computers, and robot parts, etc. can do. Therefore, it is important to contribute to the industry.
Ｌ１ リブの高さ （５０ｍｍ）
Ｌ２ リブの幅 （５０ｍｍ）
Ｌ３ 平板の厚み （３ｍｍ）
Ｌ４ リブの厚み 根元（３ｍｍ）、先端（１ｍｍ） 付け根のＲ（３ｍｍ）
平板部分の寸法 ； １１０×７０×３ｍｍ
曲げ強度、ガラス繊維含有率の測定部位は次の部位である。
ａ ；平板部分
ｂ ；中心が５ｍｍ部分のところを測定
ｃ ；中心が２０ｍｍ部分のところを測定
ｄ ；中心が４０ｍｍ部分のところを測定
L1 Rib height (50mm)
L2 rib width (50mm)
L3 Flat plate thickness (3mm)
L4 Rib thickness Root (3mm), Tip (1mm) Base R (3mm)
Dimension of flat plate part; 110 × 70 × 3mm
The measurement site | part of bending strength and glass fiber content rate is the following site | part.
a; flat plate part b; center is measured at 5mm part c; center is measured at 20mm part d; center is measured at 40mm part
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| JP2005324340A (en) * | 2004-05-12 | 2005-11-24 | Honda Motor Co Ltd | Fiber reinforced plastic and its manufacturing method |
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| JPWO2009142291A1 (en) | 2011-09-29 |
| WO2009142291A1 (en) | 2009-11-26 |
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