WO2020157894A1 - Method for manufacturing laminated composite material, method for manufacturing bag, three dimensional structure, and bag - Google Patents

Method for manufacturing laminated composite material, method for manufacturing bag, three dimensional structure, and bag Download PDF

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Publication number
WO2020157894A1
WO2020157894A1 PCT/JP2019/003320 JP2019003320W WO2020157894A1 WO 2020157894 A1 WO2020157894 A1 WO 2020157894A1 JP 2019003320 W JP2019003320 W JP 2019003320W WO 2020157894 A1 WO2020157894 A1 WO 2020157894A1
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WO
WIPO (PCT)
Prior art keywords
sheet
thermoplastic resin
laminated
composite material
carbon
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PCT/JP2019/003320
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French (fr)
Japanese (ja)
Inventor
光出 岩田
Original Assignee
Ｐｃｊ株式会社
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Publication date
Application filed by Ｐｃｊ株式会社 filed Critical Ｐｃｊ株式会社
Priority to PCT/JP2019/003320 priority Critical patent/WO2020157894A1/en
Priority to PCT/JP2020/003637 priority patent/WO2020158915A1/en
Publication of WO2020157894A1 publication Critical patent/WO2020157894A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
    • A45C—PURSES; LUGGAGE; HAND CARRIED BAGS
    • A45C5/00—Rigid or semi-rigid luggage
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer

Definitions

  • 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 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.
  • 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.
  • (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:
  • the molding die is a female mold or a male mold, and using a preform mold having a shape of a male mold or a female mold corresponding thereto, the laminated sheet body with respect to the preform mold, the release sheet, 2.
  • 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.
  • (Structure 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.
  • 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.
  • Configuration 10 The method for manufacturing a laminated composite material according to any one of configurations 1 to 9, wherein a storage portion and a lid portion of the bag are formed, and the storage portion and the lid portion are openably and closably joined. ..
  • 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.
  • 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 diagram showing a molding die used in the method for producing a laminated composite material according to the present embodiment
  • FIG. 2 is a diagram 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.
  • 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.
  • 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).
  • 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.
  • 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
  • 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.
  • 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.
  • 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 ⁇ m.
  • 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.).
  • the carbon fiber is formed to have a thickness of 300 ⁇ m, which is sufficient to reduce the protrusion of the carbon fiber to the outside.
  • 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.
  • 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.
  • 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.
  • the first thermoplastic resin layer may have a glossy surface.
  • 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.
  • the release sheet RP it is possible to reduce the damage to the mold T and extend the life of the mold T.
  • 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 ⁇ m.
  • 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.
  • carbon fiber reinforced plastic has high strength, it lacks flexibility and tends to be easily cracked by impact.
  • 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.
  • the material layer having the elastomeric property promotes the slippage at the interface between the first carbon fiber reinforced plastic layer and the second carbon fiber reinforced plastic layer, and this phenomenon gives the laminated composite material flexibility. It is what is done.
  • 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 ⁇ m. 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.
  • 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.
  • 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.
  • 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.
  • a step of stacking in this order A step of integrally removing each sheet laminated on the preform PT from the preform PT,
  • 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 mold T in this order;
  • the release sheet RP and the carbon on which the thermoplastic resin sheet PU1 is laminated on one surface of the molding die T 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.
  • 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.
  • 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.
  • 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).
  • 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.
  • 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).
  • the side surface sheets CFP21 and 22 side surfaces in the longitudinal direction
  • 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.
  • the flat sheet CFP25 is placed on the preform mold PT.
  • 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.
  • 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.
  • 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. ..
  • 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.
  • 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
  • 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.
  • 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.
  • 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.
  • 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.
  • 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).
  • 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.
  • each sheet in the molding die T makes it difficult to fit each sheet firmly to the shape of the die, which is a complicated work.
  • the preform die PT By using, the workability is excellent, and each sheet can be arranged neatly along the mold.
  • 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.
  • each method can be appropriately used for autoclave molding.
  • autoclave molding is a known technique, description thereof is omitted here, but at the time of thermocompression bonding, it is preferable to maintain a vacuum degree until the temperature becomes 80 degrees or less.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 ⁇ m, A laminated composite material is used, which is formed by thermocompressing a polyurethane sheet having a thickness of 150 ⁇ m 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.
  • each part used for the bag 1 may be made of another material (such as leather).
  • the preform mold PT 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.
  • the release sheet RP disposed between the first thermoplastic resin sheet PU1 and the molding die T 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.
  • 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. In addition, impact resistance is improved by adopting a structure in which the thermoplastic resin layer is arranged between the two carbon fiber reinforced plastic layers.
  • 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.
  • 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.
  • 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.
  • 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".
  • 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.
  • 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.
  • thermoplastic resin is taken as an example of the thermoplastic resin, but the present invention is not limited to this.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the releasability between the preform mold and the laminate must be good.
  • a release sheet may be provided between the preform mold and the laminate.

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

積層複合材の製造方法、鞄の製造方法、立体成形物及び鞄Laminated composite material manufacturing method, bag manufacturing method, three-dimensional molded article and bag
　本発明は、炭素繊維強化プラスチックを含む積層複合材の製造方法、鞄の製造方法、立体成形物及び鞄に関する。 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.
　炭素繊維強化プラスチック（ＣＦＲＰ）は、金属材料に比べ、低密度でありながら高強度であるという優れた素材であるため、製造コストが高いという問題はあるが、各分野の構造材料として広く利用されている。
　このような炭素繊維強化プラスチックに関する従来技術が、特許文献１～３によって開示されている。 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.
特開平０２－１６９６３３号公報JP-A-02-169633 特開平１０－１３８３５４号公報Japanese Patent Laid-Open No. 10-138354 特開２０１３－２０２９２３号公報JP, 2013-202923, A
　炭素繊維強化プラスチックは、軽量でありながら強度が高いというその力学的特性に基づいて利用が進んできたものであるが、その後、そのデザイン性に基づいた利用もされるようになっている。即ち、炭素繊維が織られることによって現れるパターンに意匠性を見出し、これをデザイン的に利用するものである。
　このように、デザイン的な利用にも重点がおかれるようになるに従い、より意匠性に優れた炭素繊維強化プラスチックを含む積層複合材を効率的に製造することが求められている。 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.
　本発明は、上記の点に鑑み、炭素繊維強化プラスチックを含む積層複合材であって、より意匠性に優れた積層複合材を効率的に製造することが可能な製造方法を提供することを目的とする。 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
（構成１）
　少なくとも炭素繊維強化プラスチック層と熱可塑性樹脂層を有する積層複合材の製造方法であって、成形型に対して、離型シートと、少なくとも一方の表面に熱可塑性樹脂シートが積層されたカーボンプリプレグを有する積層シート体と、をこの順で、前記離型シートと前記熱可塑性樹脂シートが接するように積層するステップと、前記成形型に対して積層された各シートを、熱圧着させるステップと、を有することを特徴とする積層複合材の製造方法。 (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:
（構成２）
　前記成形型が雌型若しくは雄型であり、これに対応する雄型若しくは雌型の形状を有するプレフォーム型を用い、当該プレフォーム型に対して前記積層シート体と、前記離型シートと、をこの順で積層するステップと、前記積層した各シートを、一体的に前記成形型にはめ込むステップと、を有することを特徴とする構成１に記載の積層複合材の製造方法。 (Configuration 2)
The molding die is a female mold or a male mold, and using a preform mold having a shape of a male mold or a female mold corresponding thereto, the laminated sheet body with respect to the preform mold, the release sheet, 2. The method for producing a laminated composite material according to the constitution 1, further comprising a step of laminating the laminated sheets in this order, and a step of integrally fitting the laminated sheets into the molding die.
（構成３）
　前記プレフォーム型に、前記成形型に対して積層させた際に最上層となるシートを配置するための基準位置が記されていることを特徴とする構成２に記載の積層複合材の製造方法。 (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. ..
（構成４）
　前記離型シートが前記熱可塑性樹脂シートに予め貼付されていることを特徴とする構成１から３の何れかに記載の積層複合材の製造方法。 (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.
（構成５）
　前記積層シート体が、第１の熱可塑性樹脂シートと、第１のカーボンプリプレグと、第２の熱可塑性樹脂シートと、第２のカーボンプリプレグと、がこの順に積層されたものであることを特徴とする構成１から４の何れかに記載の積層複合材の製造方法。 (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.
（構成６）
　前記第２の熱可塑性樹脂シートが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグのマトリクス樹脂よりも軟質の樹脂で形成されていることを特徴とする構成５に記載の積層複合材の製造方法。 (Structure 6)
6. The laminated composite material according to Structure 5, wherein the second thermoplastic resin sheet is formed of a resin softer than the matrix resin of the first carbon prepreg or the second carbon prepreg. Method.
（構成７）
　前記第２のカーボンプリプレグが、平面部シートと、これとは別体の側面部シートによって構成されることを特徴とする構成５又は６に記載の積層複合材の製造方法。 (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.
（構成８）
　前記平面部シートと前記側面部シートを相互に一部重畳させることを特徴とする構成７に記載の積層複合材の製造方法。 (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.
（構成９）
　前記第１の熱可塑性樹脂シートの厚さが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグよりも厚く、前記第２の熱可塑性樹脂シートの厚さが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグよりも薄いことを特徴とする構成５から８の何れかに記載の積層複合材の製造方法。 (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.
（構成１０）
　構成１から９の何れかに記載の積層複合材の製造方法によって、鞄の収納部と蓋部を形成し、当該収納部と蓋部を開閉可能に接合することを特徴とする鞄の製造方法。 (Configuration 10)
The method for manufacturing a laminated composite material according to any one of configurations 1 to 9, wherein a storage portion and a lid portion of the bag are formed, and the storage portion and the lid portion are openably and closably joined. ..
（構成１１）
　平面部と側面部とを有する立体成形物であって、第１の熱可塑性樹脂層と第１の炭素繊維強化プラスチック層と第２の熱可塑性樹脂層と第２の炭素繊維強化プラスチック層とを有する炭素繊維強化複合材によって形成され、前記第２の炭素繊維強化プラスチック層が、平面部炭素繊維強化プラスチック材と、これとは別体の側面部炭素繊維強化プラスチック材が接合されることによって構成されていることを特徴とする立体成形物。 (Configuration 11)
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.
（構成１２）
　前記平面部炭素繊維強化プラスチック材と前記側面部炭素繊維強化プラスチック材が相互に一部重畳されていることを特徴とする構成１１に記載の立体成形物。 (Configuration 12)
12. The three-dimensional molded article according to Structure 11, wherein the flat surface carbon fiber reinforced plastic material and the side surface carbon fiber reinforced plastic material are partially overlapped with each other.
（構成１３）
　蓋部と収納部が開閉可能に接合された鞄であって、前記蓋部若しくは収納部が、構成１１又は１２に記載の立体成形物によって形成されていることを特徴とする鞄。 (Configuration 13)
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 of the three-dimensional molded article according to Configuration 11 or 12.
　本発明の積層複合材の製造方法によれば、より意匠性に優れた積層複合材を効率的に製造することが可能となる。 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.
本発明に係る実施形態の積層複合材の製造方法に使用する成形型を示す図The figure which shows the shaping|molding die used for the manufacturing method of the laminated composite material of embodiment which concerns on this invention. 実施形態の積層複合材の製造方法に使用するプレフォーム型を示す図The figure which shows the preform type|mold used for the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材に使用される各シートを示す図The figure which shows each sheet|seat used for the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材の製造方法を示す説明図Explanatory drawing which shows the manufacturing method of the laminated composite material of embodiment. 実施形態の積層複合材によって形成された鞄の蓋部を示す図The figure which shows the lid part of the bag formed of the laminated composite material of embodiment. 実施形態の積層複合材によって形成された鞄の収納部を示す図The figure which shows the storage part of the bag formed of the laminated composite material of embodiment. 実施形態の積層複合材によって形成された鞄を示す図The figure which shows the bag formed with the laminated composite material of embodiment.
　以下、本発明の実施形態について、図面を参照しながら具体的に説明する。なお、以下の実施形態は、本発明を具体化する際の一形態であって、本発明をその範囲内に限定するものではない。 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.
　本実施形態は、炭素繊維強化プラスチック層と熱可塑性樹脂層を有する積層複合材によって立体成形物を形成する積層複合材の製造方法に関し、立体成形物の具体例として鞄の蓋部を用いて説明する。 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.
　図１は本実施形態の積層複合材の製造方法に使用する成形型を示す図であり、図２はプレフォーム型を示す図である。本実施形態の積層複合材は、炭素繊維強化プラスチック層と熱可塑性樹脂層を有する積層構造物であり、カーボンプリプレグと熱可塑性樹脂シートを成形状態にて積層し、これをオートクレーブ製法による熱圧着によって成形するものである。成形型Ｔは、カーボンプリプレグと熱可塑性樹脂シートを成形状態にて積層するための成形型である。
　本実施形態は鞄の一例としてのトラベルケースの蓋部を製造するものであり、本実施形態のトラベルケースは直方体状の形状を有し、その蓋部としては、上面部（平面部）と比較的高さの低い側面部を有する形状を基本的な態様として有している。即ち、高さの低い直方体の底面が無いことにより、下側に開口している形状を、基本的な態様としている。
　このような蓋部を成形するための成形型Ｔは、図１に示されるように、矩形のトレー状の形状を有し、その内面に沿ってカーボンプリプレグと熱可塑性樹脂シートが積層されることにより、上記形状の蓋部を成形するものである。 FIG. 1 is a diagram showing a molding die used in the method for producing a laminated composite material according to the present embodiment, and FIG. 2 is a diagram 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.
　プレフォーム（preform）型ＰＴは、成形型Ｔに対してカーボンプリプレグと熱可塑性樹脂シートを成形状態で積層する作業を効率化及び高精度化するためのツールであり、図２に示されるように、成形型Ｔ（雌型）に対応する雄型の形態を有する。
　プレフォーム型ＰＴの側面には、成形型Ｔに対して積層させた際に最上層となるシート（本実施形態では、第２のカーボンプリプレグＣＦＰ２）を配置するための基準位置ＰＴｌ１が記されている。また、各シートの下端下限位置（シート端がこれを超えないようにする基準位置）である基準位置ＰＴｌ２が記されている。
　本実施形態における成形型Ｔは炭素繊維強化プラスチックで形成されており、プレフォーム型ＰＴも炭素繊維強化プラスチックにて形成されている。成形型Ｔ及びプレフォーム型ＰＴを、線膨張係数が低く、合成の高い炭素繊維強化プラスチックにて形成することにより、プレフォーム型ＰＴに積層した積層シート体を成形型Ｔに移す際に正確性が得られる。また、炭素繊維強化プラスチックは軽量かつ剛性を有するため、成形型Ｔ及びプレフォーム型ＰＴの取り扱いの作業性に優れるものである。なお、成形型Ｔやプレフォーム型ＰＴを形成する素材は、例えばステンレス鋼を用いる等、適宜適切な材料を選択することができる。 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.
　図３は、実施形態の積層複合材に形成するための各シートを示す図である。
　本実施形態の積層複合材は、第１の熱可塑性樹脂層（本実施形態ではポリウレタン層）と第１の炭素繊維強化プラスチック層と第２の熱可塑性樹脂層（本実施形態ではポリウレタン層）と第２の炭素繊維強化プラスチック層の４層構造を有しており、これを形成するためのシートとして、第１の熱可塑性樹脂シートＰＵ１と、第１のカーボンプリプレグＣＦＰ１と、第２の熱可塑性樹脂シートＰＵ２と、第２のカーボンプリプレグＣＦＰ２を用いる。
　また、上記各シートを積層してオートクレーブによって積層複合材（蓋部）を成形する際に、離型シートＲＰを用いる。
　各シートは、矩形形状の各角部に切り込みが形成されている形状を有しており、上面部と側面部を有する蓋の展開図としての形状にプレカットされている。 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.
　第１の熱可塑性樹脂シートＰＵ１は、３００μｍの厚さを有するポリウレタンシートである。第１の熱可塑性樹脂シートＰＵ１は透光性を有する。第１の熱可塑性樹脂シートＰＵ１は、製品（鞄）としての表面側（意匠面）に位置するものであり、鞄表面の質感や触感を向上させ、且つ、安全性を向上（破損した際等に、カーボン繊維がささくれ状に外部に突出することを低減）させるために十分な厚さとして３００μｍの厚さで形成される。
　また、第１の熱可塑性樹脂シートＰＵ１によって意匠面に形成されるポリウレタン層は、塗装面としての機能も有し、塗装レスでの製品化を可能とする。従来、炭素繊維強化プラスチックは、その製造上、表面に細かな気泡等が生じ、これが原因でその表面をきれいに塗装することが難しい（何層もの塗り重ねを要し、非常にコストがかかる）ものであったが、本実施形態によれば、表面にポリウレタン層が形成されることにより、別途の塗装工程を不要とすることができるものである。なお、第１の熱可塑性樹脂シートＰＵ１によって意匠面に形成されるポリウレタン層に対して塗装をすることも勿論可能である。ポリウレタン層によって、炭素繊維強化プラスチックの表面の気泡がカバーされるため、美しい塗装面を容易に得ることができるものである。 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.
　離型シートＲＰは、第１の熱可塑性樹脂シートＰＵ１と成形型Ｔの間に配され、第１の熱可塑性樹脂シートＰＵ１の表面を保護すると共に、その表面の意匠性を向上させるためのものであり、耐熱紙によって形成される。
　第１の熱可塑性樹脂シートＰＵ１は、成形型Ｔに接する側に配されるため、成形型Ｔに僅かであっても傷等があると、オートクレーブで熱圧着される際にこの傷が転写されて第１の熱可塑性樹脂層の表面に傷となって表れるおそれがある。また成形型Ｔにゴミや汚れが付着していると、同様にゴミや汚れが第１の熱可塑性樹脂層の表面に表れるおそれがある。離型シートＲＰを用いることにより、このような問題を低減することができる。
　また、離型シートＲＰと第１の熱可塑性樹脂シートＰＵ１を積層してオートクレーブで熱圧着することにより、離型シートＲＰの表面の微細な凹凸が転写され、第１の熱可塑性樹脂層に表面にマット感を与えることができる。なお、離型シートＲＰとして表面が平滑なシートを用いることによって、第１の熱可塑性樹脂層に表面をツヤありにすることもできる。
　このように、離型シートＲＰを用いることにより、第１の熱可塑性樹脂シートＰＵ１（第１の熱可塑性樹脂層）の表面を保護すると共に、その表面の意匠性を向上させることができる。
　加えて、離型シートＲＰを使用することで成形型Ｔのダメージを低減させ成形型Ｔの寿命を延ばすこともできる。
　なお、本実施形態においては、離型シートＲＰは、第１の熱可塑性樹脂シートＰＵ１に予め貼付された状態にて、プレカットされており、以下で説明する作業工程においては、離型シートＲＰと第１の熱可塑性樹脂シートＰＵ１は、一体的に扱われるものである。 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. 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.
　第２の熱可塑性樹脂シートＰＵ２は、１５０μｍの厚さを有するポリウレタンシートである。第２の熱可塑性樹脂シートＰＵ２は、第１のカーボンプリプレグＣＦＰ１と第２のカーボンプリプレグＣＦＰ２の間に配され、熱圧着後は、第１の炭素繊維強化プラスチック層と第２の炭素繊維強化プラスチック層の間に、第２の熱可塑性樹脂層を形成するものである。
　炭素繊維強化プラスチックは、その強度が高い反面、柔軟性に欠け、衝撃に対して割れやすいという傾向がある。これに対し、２層の炭素繊維強化プラスチック層の間に、エラストマー性を有する材料層を形成した積層複合材とすることにより、炭素繊維強化プラスチックの高い強度を備えつつ、柔軟性も付与され、耐衝撃性が向上されるものである。即ち、エラストマー性を有する材料層によって、第１の炭素繊維強化プラスチック層と第２の炭素繊維強化プラスチック層の界面の滑りが助長され、この現象によって積層複合材に柔軟性を持たせる結果が得られるものである。当該目的に資するためには、第２の熱可塑性樹脂シートは、カーボンプリプレグのマトリクス樹脂よりも軟質の樹脂で形成されることが好ましい。 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 the slippage at the interface between the first carbon fiber reinforced plastic layer and the second carbon fiber reinforced plastic layer, and this phenomenon gives the laminated composite material flexibility. It is what is done. 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.
　第１のカーボンプリプレグＣＦＰ１及び第２のカーボンプリプレグＣＦＰ２は、厚さが２００μｍのカーボンプリプレグである。従って、本実施形態では、第１の熱可塑性樹脂シートＰＵ１の厚さが、第１のカーボンプリプレグＣＦＰ１及び第２のカーボンプリプレグＣＦＰ２よりも厚く、第２の熱可塑性樹脂シートＰＵ２の厚さが、第１のカーボンプリプレグＣＦＰ１及び第２のカーボンプリプレグＣＦＰ２よりも薄いものである。
　第１のカーボンプリプレグＣＦＰ１は、他の各シートと同様の形状である。
　一方、第２のカーボンプリプレグＣＦＰ２は、平面部シートＣＦＰ２５と、これとは別体の各側面部シートＣＦＰ２１～ＣＦＰ２４によって構成される。即ち、蓋部の上面部を構成する平面部シートＣＦＰ２５と、蓋部の各側面部を構成する各側面部シートＣＦＰ２１～ＣＦＰ２４が、別体として形成されている。後に説明するように、平面部シートＣＦＰ２５と、各側面部シートＣＦＰ２１～ＣＦＰ２４が接合される辺において、相互に一部重畳させて接合されるものであり、このように一部重畳させて接合された状態で、他の各シートと同様の形状となる。 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.
　次に、本実施形態の積層複合材（鞄の蓋部）の製造方法について、図４～１０を参照しながら説明する。
　大まかな作業の流れとしては、
　プレフォーム型ＰＴに対して、第２のカーボンプリプレグＣＦＰ２と第２の熱可塑性樹脂シートＰＵ２と第１のカーボンプリプレグＣＦＰ１と第１の熱可塑性樹脂シートＰＵ１の積層シート体と、離型シートＲＰと、をこの順で積層するステップと、
　プレフォーム型ＰＴに対して積層した各シートを、一体的にプレフォーム型ＰＴから取り外すステップと、
　当該取り外した一体的な各シートの積層体を、成形型Ｔにはめ込むことにより、離型シートＲＰと、第１の熱可塑性樹脂シートＰＵ１と、第１のカーボンプリプレグＣＦＰ１と、第２の熱可塑性樹脂シートＰＵ２、と第２のカーボンプリプレグＣＦＰ２のと、をこの順で成形型Ｔに対して積層させるステップと、
　を順次行うものである。
　プレフォーム型ＰＴに対して積層した各シートの積層体を成形型Ｔにはめ込むことにより、成形型Ｔに対して、離型シートＲＰと、一方の表面に熱可塑性樹脂シートＰＵ１が積層されたカーボンプリプレグを有する積層シート体と、がこの順で、離型シートＲＰと熱可塑性樹脂シートＰＵ１が接するように積層されることになる。 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 mold 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.
　図４～６は、プレフォーム型ＰＴに対して、第２のカーボンプリプレグＣＦＰ２を配置する作業を説明する図である。
　前述のごとく、第２のカーボンプリプレグＣＦＰ２は、平面部シートＣＦＰ２５と、これとは別体の各側面部シートＣＦＰ２１～ＣＦＰ２４によって構成されている。
　図４に示されるように、先ず、側面部シートＣＦＰ２１（長手方向の側面）をプレフォーム型ＰＴに対して配置する。プレフォーム型ＰＴには、その側面に、第２のカーボンプリプレグＣＦＰ２を配置するための基準位置ＰＴｌ１がけがかれており、この基準位置ＰＴｌ１に合わせて側面部シートＣＦＰ２１をプレフォーム型ＰＴに対して配置する。
　側面部シートＣＦＰ２１は、プレフォーム型ＰＴの角部（即ち鞄の蓋部の角部）を覆って上面部に至るだけの高さ方向の寸法を有している。この点は、各側面部シートＣＦＰ２１～ＣＦＰ２４で同様である。
　側面部シートＣＦＰ２１と同じようにして、他端側の側面部シートＣＦＰ２２（長手方向の側面）をプレフォーム型ＰＴに対して配置する（図示省略）。
　なお、カーボンプリプレグや熱可塑性樹脂シートは、それ自体がある程度の粘着性を有しており、当該粘着性に基づいて、プレフォーム型ＰＴへの貼り付けや、各シートの積層時の貼り付けが行われる。 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.
　次に、図５に示されるように、側面部シートＣＦＰ２３（短手方向の側面）をプレフォーム型ＰＴに対して配置する。側面部シートＣＦＰ２１と同様に、基準位置ＰＴｌ１に合わせて側面部シートＣＦＰ２３をプレフォーム型ＰＴに対して配置する。
　また、側面部シートＣＦＰ２３と同じようにして、他端側の側面部シートＣＦＰ２４（短手方向の側面）をプレフォーム型ＰＴに対して配置する（図示省略）。
　本実施形態では、図５（ｂ）に示されるように、側面部シートＣＦＰ２１、２２（長手方向の側面）と、側面部シートＣＦＰ２３、２４（短手方向の側面）は、角部付近でそれぞれの端部が突き当たるように配置される。 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.
　次に、図６に示されるように、平面部シートＣＦＰ２５をプレフォーム型ＰＴに対して配置する。平面部シートＣＦＰ２５の配置では、その角部の切欠き部分を基準位置ＰＴｌ１に合わせて位置決めを行い、平面部シートＣＦＰ２５の中心部から側面に向かって貼りつけるように配置する。
　平面部シートＣＦＰ２５は、プレフォーム型ＰＴの角部（即ち鞄の蓋部の角部）を覆って各側面部に至るだけの寸法を有している。 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.
　平面部シートＣＦＰ２５と各側面部シートＣＦＰ２１～ＣＦＰ２４を別体とすることにより、プレフォーム型ＰＴ（若しくは成形型Ｔ）に対して、シートを配置する際の作業性に優れ、角部のシワやツッパリ(型に沿わない）が生じることを低減することもできる。また、各側面部シートＣＦＰ２１～ＣＦＰ２４を、例えば他のシートをカットした後の端材から形成することも可能であり、材料の使用効率に優れる。
　加えて、上記のように平面部シートＣＦＰ２５と各側面部シートＣＦＰ２１～ＣＦＰ２４を一部重畳させて接合することにより、角部においてカーボンプリプレグが積層される構造となり、角部の強度が向上される。トラベルケースのような略直方体状の形態を有する鞄においては、角部に負荷がかかることが多い。これに対し、上記構成によれば、角部の強度が強化されるため好適である。
　なお、ここでは、側面部シートＣＦＰ２１～２４の配置において、側面部シートＣＦＰ２１～２４の順番で配置するものを例としているが、側面部シートＣＦＰ２１～ＣＦＰ２４の配置の順番は任意であって構わない。また、平面部シートＣＦＰ２５を先に配置して、その後で側面部シートＣＦＰ２１～２４を配置するものであっても構わない。 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.
　次に、図７に示されるように、第２のカーボンプリプレグＣＦＰ２が貼り付けられたプレフォーム型ＰＴ上に、第２の熱可塑性樹脂シートＰＵ２を配置する。
　第２の熱可塑性樹脂シートＰＵ２の位置合わせは、第２のカーボンプリプレグＣＦＰ２の外周形状（若しくは、プレフォーム型ＰＴの基準位置ＰＴｌ１）と、第２の熱可塑性樹脂シートＰＵ２の外周形状を合わせることによって行う。 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
　次に、第２のカーボンプリプレグＣＦＰ２と第２の熱可塑性樹脂シートＰＵ２がこの順に積層されたプレフォーム型ＰＴ上に、第１のカーボンプリプレグＣＦＰ１を配置する。
　第１のカーボンプリプレグＣＦＰ１の位置合わせは、積層されている各シートの外周形状（若しくは、プレフォーム型ＰＴの基準位置ＰＴｌ１）と、第１のカーボンプリプレグＣＦＰ１の外周形状を合わせることによって行う。
　なお、第１のカーボンプリプレグＣＦＰ１の配置において、図８に示されるように、プレフォーム型ＰＴの短辺が上側と下側に配置され、長辺が左側と右側に配置された位置において、第１のカーボンプリプレグＣＦＰ１のカーボン繊維の網目方向が右上がりとなるように配置する。 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.
　次に、第２のカーボンプリプレグＣＦＰ２と第２の熱可塑性樹脂シートＰＵ２と第１のカーボンプリプレグＣＦＰ１がこの順に積層されたプレフォーム型ＰＴ上に、離型シートＲＰが貼付されている第１の熱可塑性樹脂シートＰＵ１を配置する。この際に、図９に示されるように、離型シートＲＰが上面側で、第２の熱可塑性樹脂シートＰＵ２がプレフォーム型ＰＴ側となるように配置する。
　離型シートＲＰが貼付されている第１の熱可塑性樹脂シートＰＵ１の位置合わせは、積層されている各シートの外周形状（若しくは、プレフォーム型ＰＴの基準位置ＰＴｌ１）と、離型シートＲＰが貼付されている第１の熱可塑性樹脂シートＰＵ１の外周形状を合わせることによって行う。 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.
　次に、上記工程によって、プレフォーム型ＰＴ上に、第２のカーボンプリプレグＣＦＰ２と第２の熱可塑性樹脂シートＰＵ２と第１のカーボンプリプレグＣＦＰ１と第１の熱可塑性樹脂シートＰＵ１と離型シートＲＰがこの順に積層された積層体を、プレフォーム型ＰＴから一体的に剥がし、これを成形型Ｔ内にはめ込む（図１０）。
　図１０に示されるように、積層体を天地逆にして入れ替えることにより、成形型Ｔ内で、離型シートＲＰと、熱可塑性樹脂シートＰＵ１と、第１のカーボンプリプレグＣＦＰ１と、第２の熱可塑性樹脂シートＰＵ２と、第２のカーボンプリプレグＣＦＰ２が、この順で積層されることになる。
　成形型Ｔ内への各シートの配置は、特にその角部等において、各シートをしっかりと型の形状に沿わせることが難しく、煩雑な作業となるが、本実施形態では、プレフォーム型ＰＴを用いることにより、作業性に優れ、且つ、各シートを型内にしっかりと沿わせてきれいに配置することができる。 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.
Disposing each sheet in the molding die T, especially at the corners and the like, makes it difficult to fit each sheet firmly to the shape of the die, which is a complicated work. However, in the present embodiment, the preform die PT By using, the workability is excellent, and each sheet can be arranged neatly along the mold.
　以上により、成形型Ｔ内に各シートが成形状態にて積層され、これをオートクレーブ製法による熱圧着によって成形し、成形型Ｔから成形品を脱型することで、積層複合材によって形成された立体成形物である蓋部が得られる。
　なお、オートクレーブ成形については適宜各手法を用いることができる。オートクレーブ成形は公知の技術であり、ここでの説明を省略するが、熱圧着時には、その温度が８０度以下になるまで真空度を保つことが好ましい。本実施形態の積層複合材においては、熱可塑性樹脂を用いており、８０度より高い温度下で真空度を緩めると、離型紙ＲＰによる艶消し感の転写にムラが発生する可能性があるためである。 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. Although autoclave molding is a known technique, description thereof is omitted here, but at the time of thermocompression bonding, it is preferable to maintain a vacuum degree until the temperature becomes 80 degrees or less. 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.
　図１１は、上記によって成形された蓋部１１を示す各平面図である。
　また、図１２には、鞄（トラベルケース）の収納部１２の各平面図を示した。当該収納部１２は、蓋部１１と同様の積層構造を有し、上記説明した蓋部１１と同様の製造工程によって成形されたものである。蓋部１１と収納部１２の形状の違いによる型の形状の相違や、各シートの形状の相違はあるが、プレフォーム型を用いて各シートを積層し、これによって積層された積層体を、成形型へと移し替えるものであり、蓋部１１の製造と同様の概念であるため、ここでの詳しい説明を省略する。 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.
　図１３には、蓋部１１と収納部１２を用いて形成された鞄１を示した。
　鞄１は、蓋部１１と収納部１２に、それぞれの角部等にあてる各パーツの取り付けや、内張り等を施し、さらに、留め具（鍵）等の各金具、取っ手や、装飾具などの取り付け、及び、蓋部１１と収納部１２をヒンジ１３によって開閉可能に接合すること等によって、形成される。 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.
　なお、本実施形態では、鞄に取り付けるベルトについて、炭素繊維によって織られた炭素繊維織物の上面及び下面に熱可塑性樹脂シート（本実施形態では、上面側（意匠面側）に３００μｍの厚さ、下面側に１５０μｍの厚さのポリウレタンシート）を熱圧着させることで形成された積層複合材が使用されている。
　“炭素繊維によって織られた炭素繊維織物”とはカーボンプリプレグのマトリクス樹脂が無いものである。これの両面に、透光性の熱可塑性樹脂シートが熱圧着された積層複合材は、非常に柔軟で革に似た手触りの素材となり、表面の見た目としてはカーボン素材（炭素繊維強化プラスチック）と同様である。即ち、見た目はカーボン素材でテクスチャとしては革に近い、高級感を感じさせる素材である。
　このような素材によって、鞄１に取り付けるベルトを形成することにより、蓋部１１と収納部１２のカーボン素材の見た目とマッチし、より高級感のある製品とすることができる。ベルトの他、鞄１に使用する各パーツ（蓋部１１と収納部１２の角部等にあてる各パーツや、取っ手等）にも上記積層複合材を用いる等してもよい。なお、ベルト等の鞄１に使用する各パーツを他の素材（例えば革等）で形成するものであっても勿論よい。 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).
　以上のごとく、本実施形態によれば、プレフォーム型ＰＴを用いることにより、成形型Ｔに対してカーボンプリプレグと熱可塑性樹脂シートを成形状態で積層する作業を効率化及び高精度化することができる。
　また、プレフォーム型ＰＴには、基準位置ＰＴｌ１が記されているため、各シートの配置を精度よく行うことができる。 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.
　本実施形態によれば、第１の熱可塑性樹脂シートＰＵ１と成形型Ｔの間に配される離型シートＲＰを用いることにより、第１の熱可塑性樹脂シートＰＵ１の表面を保護すると共に、その表面の意匠性を向上することができる。また、離型シートＲＰを使用することで成形型Ｔのダメージを低減させ成形型Ｔの寿命を延ばすこともできる。 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.
　本実施形態によれば、第１の熱可塑性樹脂層がカーボン素材（第１の炭素繊維強化プラスチック層）の表面に形成されるため、表面の質感や触感を向上させ、且つ、安全性を向上することができる。さらに、表面への塗装を不要とすることができ、表面に塗装を施す際においても美しい塗装面を容易に得ることができる。
　また、熱可塑性樹脂層を、２層の炭素繊維強化プラスチック層の間に配する構造としていることにより、耐衝撃性が向上される。 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.
In addition, impact resistance is improved by adopting a structure in which the thermoplastic resin layer is arranged between the two carbon fiber reinforced plastic layers.
　本実施形態によれば、第２のカーボンプリプレグＣＦＰ２が、平面部シートＣＦＰ２５と、これとは別体の各側面部シートＣＦＰ２１～ＣＦＰ２４によって構成されるため、プレフォーム型ＰＴに対して、シートを配置する際の作業性に優れ、材料の使用効率においても優れている。また、平面部シートＣＦＰ２５と各側面部シートＣＦＰ２１～ＣＦＰ２４を一部重畳させて接合することにより、角部においてカーボンプリプレグが積層される構造となる。
　これが熱圧着されることで、角部において平面部炭素繊維強化プラスチック材と側面部炭素繊維強化プラスチック材が積層された構造となるため、角部の強度が向上される。 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.
　なお、本実施形態においては、積層複合材として、第１の熱可塑性樹脂層と第１の炭素繊維強化プラスチック層と第２の熱可塑性樹脂層と第２の炭素繊維強化プラスチック層の４層構造であるものを例としているが、本発明をこれに限るものでは無く、“少なくとも炭素繊維強化プラスチック層と熱可塑性樹脂層を有する積層複合材”であればよい。例えば、熱可塑性樹脂層と炭素繊維強化プラスチック層の繰り返し数を増減してもよいし、他の材料層（例えば塗装膜）を備えるものであってもよい。
　本実施形態では、積層複合材の製品としての表面（意匠面）が一方側だけである（他方（内面）側は内張りが施される）ため、第２の炭素繊維強化プラスチック層の表面には熱可塑性樹脂層を積層していないが、素材の両面が意匠面となる製品等においては、両面に熱可塑性樹脂層を積層するものであってよい。その際には、その製造工程において、両面に離型シートを配すると好適である。 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.
　また、本実施形態では、熱可塑性樹脂として、ポリウレタンを例としているが、本発明をこれに限るものではない。２層の炭素繊維強化プラスチック層の間に配される熱可塑性樹脂層については、エラストマー性を有し、炭素繊維強化プラスチックのマトリクス樹脂よりも軟質の樹脂である各種の樹脂を用いることができる。
　また、表面（意匠面）側に設けられる熱可塑性樹脂層については、意匠性、質感、手触り、安全性等の設計思想に即した各種の樹脂を用いることができる。 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.
　本実施形態では、立体成形物として鞄の蓋部（及び収納部）を例として説明したが、本発明は鞄に限らず多様な立体成形物に適用することができる。 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.
　本実施形態では、プレフォーム型上に積層した積層体をプレフォーム型から剥がして、成形型に入れるものを例としたが、プレフォーム型と積層体との離型性が良いようであれば、プレフォーム型上に積層した積層体ごと成形型に入れ、この状態でプレフォーム型だけを抜くような工程であってもよい。また、プレフォーム型上に積層した積層体ごと成形型に入れ、このまま（プレフォーム型ごと）、オートクレーブ成形による熱圧着を行っても良い。ただし、これらの場合には、プレフォーム型と積層体との離型性が良い必要がある。離型性向上のために、プレフォーム型と積層体との間に離型シートを設けるようにしてもよい。 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.
　１．．．鞄
　　１１．．．蓋部（立体成形物）
　　１２．．．収納部（立体成形物）
　ＣＦＰ１．．．第１のカーボンプリプレグ
　ＣＦＰ２．．．第２のカーボンプリプレグ
　　ＣＦＰ２１～２４．．．側面部シート
　　ＣＦＰ２５．．．平面部シート
　ＰＵ１．．．第１の熱可塑性樹脂シート
　ＰＵ２．．．第２の熱可塑性樹脂シート
　ＲＰ．．．離型シート
　Ｔ．．．成形型
　ＰＴ．．．プレフォーム型
　　ＰＴｌ１．．．基準位置 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

Claims (13)

  1. 　少なくとも炭素繊維強化プラスチック層と熱可塑性樹脂層を有する積層複合材の製造方法であって、
    　成形型に対して、離型シートと、少なくとも一方の表面に熱可塑性樹脂シートが積層されたカーボンプリプレグを有する積層シート体と、をこの順で、前記離型シートと前記熱可塑性樹脂シートが接するように積層するステップと、
    　前記成形型に対して積層された各シートを、熱圧着させるステップと、
    　を有することを特徴とする積層複合材の製造方法。     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:
  2. 　前記成形型が雌型若しくは雄型であり、これに対応する雄型若しくは雌型の形状を有するプレフォーム型を用い、当該プレフォーム型に対して前記積層シート体と、前記離型シートと、をこの順で積層するステップと、
    　前記積層した各シートを、一体的に前記成形型にはめ込むステップと、
    　を有することを特徴とする請求項１に記載の積層複合材の製造方法。     The molding die is a female mold or a male mold, and using a preform mold having a shape of a male mold or a female mold corresponding thereto, the laminated sheet body with respect to the preform mold, the release sheet, Stacking in this order,
    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. 　前記プレフォーム型に、前記成形型に対して積層させた際に最上層となるシートを配置するための基準位置が記されていることを特徴とする請求項２に記載の積層複合材の製造方法。 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.
  4. 　前記離型シートが前記熱可塑性樹脂シートに予め貼付されていることを特徴とする請求項１から３の何れかに記載の積層複合材の製造方法。 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.
  5. 　前記積層シート体が、第１の熱可塑性樹脂シートと、第１のカーボンプリプレグと、第２の熱可塑性樹脂シートと、第２のカーボンプリプレグと、がこの順に積層されたものであることを特徴とする請求項１から４の何れかに記載の積層複合材の製造方法。 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.
  6. 　前記第２の熱可塑性樹脂シートが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグのマトリクス樹脂よりも軟質の樹脂で形成されていることを特徴とする請求項５に記載の積層複合材の製造方法。 The laminated composite material according to claim 5, wherein the second thermoplastic resin sheet is formed of a resin softer than a matrix resin of the first carbon prepreg or the second carbon prepreg. Production method.
  7. 　前記第２のカーボンプリプレグが、平面部シートと、これとは別体の側面部シートによって構成されることを特徴とする請求項５又は６に記載の積層複合材の製造方法。 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.
  8. 　前記平面部シートと前記側面部シートを相互に一部重畳させることを特徴とする請求項７に記載の積層複合材の製造方法。 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.
  9. 　前記第１の熱可塑性樹脂シートの厚さが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグよりも厚く、前記第２の熱可塑性樹脂シートの厚さが、前記第１のカーボンプリプレグ又は第２のカーボンプリプレグよりも薄いことを特徴とする請求項５から８の何れかに記載の積層複合材の製造方法。 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.
  10. 　請求項１から９の何れかに記載の積層複合材の製造方法によって、鞄の収納部と蓋部を形成し、当該収納部と蓋部を開閉可能に接合することを特徴とする鞄の製造方法。 The method for manufacturing a laminated composite material according to any one of claims 1 to 9, wherein a storage portion and a lid portion of the bag are formed, and the storage portion and the lid portion are openably and closably joined to each other. Method.
  11. 　平面部と側面部とを有する立体成形物であって、
    　第１の熱可塑性樹脂層と第１の炭素繊維強化プラスチック層と第２の熱可塑性樹脂層と第２の炭素繊維強化プラスチック層とを有する炭素繊維強化複合材によって形成され、
    　前記第２の炭素繊維強化プラスチック層が、平面部炭素繊維強化プラスチック材と、これとは別体の側面部炭素繊維強化プラスチック材が接合されることによって構成されていることを特徴とする立体成形物。     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.
  12. 　前記平面部炭素繊維強化プラスチック材と前記側面部炭素繊維強化プラスチック材が相互に一部重畳されていることを特徴とする請求項１１に記載の立体成形物。 The three-dimensional molded article according to claim 11, wherein the flat surface carbon fiber reinforced plastic material and the side surface carbon fiber reinforced plastic material are partially overlapped with each other.
  13. 　蓋部と収納部が開閉可能に接合された鞄であって、
    　前記蓋部若しくは収納部が、請求項１１又は１２に記載の立体成形物によって形成されていることを特徴とする鞄。     A bag in which a lid part and a storage part are openably and closably joined,
    The bag according to claim 11, wherein the lid portion or the storage portion is formed of the three-dimensional molded article according to claim 11.
PCT/JP2019/003320 2019-01-31 2019-01-31 Method for manufacturing laminated composite material, method for manufacturing bag, three dimensional structure, and bag WO2020157894A1 (en)

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