JP2015030272A - Carbon fiber-containing nonwoven fabric structure and laminate structure of the same and method for producing them - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carbon fiber-containing nonwoven fabric structure improved in mechanical strength.SOLUTION: There is provided a carbon fiber-containing nonwoven fabric laminate structure 40 composed of a laminate of a carbon fiber-containing nonwoven fabric 2 and a thermoplastic resin sheet 3 which are bonded together by heating and molding. In the carbon fiber-containing nonwoven fabric 2, a PVB (polyvinylbutyral) resin is immersed in a space between each of the fibers in the one surface or both surfaces. The PVB resin is melted during heating and forming a laminate of the carbon fiber-containing nonwoven fabric 2 and the thermoplastic resin sheet 3 to improve adhesiveness of the laminate and mechanical strength of the laminate structure 40.

Description

  The present invention relates to a carbon fiber-containing nonwoven fabric structure, a laminated structure thereof, and a method for producing them.

  A conventional carbon fiber-containing injection-molded structure is obtained by molding a thermoplastic resin in which a large number of carbon fibers are kneaded with an injection molding machine (for example, see Patent Document 1). In this case, in order to perform injection molding easily, the carbon fiber has a short length.

  Specifically, a thermoplastic resin in which a large number of carbon fibers are kneaded is injected into the molding die through injection molding holes, and the injection molded carbon fiber-containing injection molded structure is molded after cooling and solidification. Removed from the mold.

  However, the conventional carbon fiber-containing injection-molded structure has a low mechanical strength because all of the many carbon fibers are arranged radially around the corresponding portion of the injection-molded hole.

Japanese Patent Laid-Open No. 2003-238818

  An object of the present invention is to provide a carbon fiber-containing nonwoven fabric structure having a high mechanical strength, a laminated structure thereof, and a production method thereof.

  In order to achieve the above object, the carbon fiber-containing nonwoven fabric structure according to claim 1 comprises a carbon fiber-containing nonwoven fabric including thermoplastic resin fibers and a large number of carbon fibers, and a gap between the fibers is impregnated with PCB resin. A carbon fiber-containing nonwoven fabric structure, wherein the carbon fiber-containing nonwoven fabric is heat-molded.

  The carbon fiber-containing nonwoven fabric laminate structure according to claim 6 is a laminate of a carbon fiber-containing nonwoven fabric and a thermoplastic resin sheet that includes a thermoplastic resin fiber and a large number of carbon fibers, and a gap between each fiber is impregnated with a PCB resin. Thus, the laminate is heat-molded.

  In order to achieve the above object, a method for producing a carbon fiber-containing nonwoven fabric structure according to claim 12 is a method for producing a carbon fiber-containing nonwoven fabric structure comprising a thermoplastic resin fiber and a number of carbon fibers, A paper making process for preparing a carbon fiber-containing non-woven fabric by paper-making a plastic resin fiber and a large number of carbon fibers in a liquid, and applying a solvent containing PCB resin to at least one surface of the paper-made carbon fiber-containing non-woven fabric And an impregnation step of impregnating the PCB resin into the gaps between the fibers of the carbon fiber-containing nonwoven fabric, and a thermoforming step of thermoforming the carbon fiber-containing nonwoven fabric impregnated with the PCB resin.

  In order to achieve the above object, a method for producing a carbon fiber-containing nonwoven fabric laminate structure according to claim 13 is a method for producing a carbon fiber-containing nonwoven fabric laminate structure of a carbon fiber-containing nonwoven fabric comprising thermoplastic resin fibers and a large number of carbon fibers. A papermaking process for preparing a carbon fiber-containing nonwoven fabric by papermaking the thermoplastic resin fiber and the multiple carbon fibers in a liquid, and the carbon fiber-containing nonwoven fabric obtained by papermaking a solvent containing a PCB resin. An impregnation step in which the PCB resin is impregnated into at least one surface of the carbon fiber-containing nonwoven fabric, and a thermoplastic resin sheet is applied to at least one surface of the carbon fiber-containing nonwoven fabric impregnated with the PCB. A lamination step of sheeting and a thermoforming step of thermoforming the carbon fiber-containing nonwoven fabric on which the thermoplastic resin sheet is laminated. To.

  The carbon fiber-containing nonwoven fabric structure according to claim 1 has high mechanical strength.

  The carbon fiber-containing nonwoven fabric laminated structure according to claim 6 has high mechanical strength.

  According to the method for producing a carbon fiber-containing nonwoven fabric structure according to claim 12, a carbon fiber-containing nonwoven fabric structure having high mechanical strength can be produced.

  According to the method for producing a carbon fiber-containing nonwoven fabric laminate structure according to claim 13, a carbon fiber-containing nonwoven fabric laminate structure having high mechanical strength can be produced.

It is an external appearance perspective view of the carbon fiber containing nonwoven fabric laminated structure which concerns on embodiment of this invention. It is sectional drawing of the carbon fiber containing nonwoven fabric laminated structure which follows the line II-II of FIG. It is sectional drawing of the carbon fiber containing nonwoven fabric laminated structure which follows the line III-III of FIG. It is a perspective view of the carbon fiber containing nonwoven fabric in FIG. It is a figure used for demonstrating the manufacturing method of the carbon fiber containing nonwoven fabric laminated structure of FIG. It is a figure used for demonstrating the process 1 in FIG.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is an external perspective view of a carbon fiber-containing nonwoven fabric laminated structure according to an embodiment of the present invention.

  In FIG. 1, a carbon fiber-containing non-woven fabric laminated structure 40 (hereinafter sometimes simply referred to as “laminated structure 40”) is a casing having an inverted basin structure, and one protrusion 41 and one opening at the bottom of the inverted basin structure. Part 42.

  The cross section of the protrusion 41 is shown in FIG. 2 as a cross-sectional view along line II-II in FIG. 1, and the cross section of the opening 42 is shown in FIG. 3 as a cross-sectional view along line III-III in FIG. .

  The laminated structure 40 is composed of a laminate of the carbon fiber-containing nonwoven fabric 2 and the thermoplastic resin sheet 3 that are bonded to each other by thermoforming.

  The thermoplastic resin sheet is a sheet made of a thermoplastic resin. This thermoplastic resin is a polyolefin resin such as polyethylene and polypropylene, a polyester resin such as polyethylene terephthalate, a polyamide resin such as nylon, and a polymethacrylate such as polymethyl methacrylate. It may be made of a resin, polystyrene resin, and polycarbonate resin, and may be made of a copolymer such as acrylonitrile-butadiene-styrene (ABS resin).

  As shown in FIG. 4, the carbon fiber-containing nonwoven fabric 2 is composed of thermoplastic resin fibers 51 and a large number of carbon fibers 52 that are mixed with each other.

  Specifically, each fiber of the thermoplastic resin fiber 51 has a thickness of 1 to 50 μm and a length of 1 to 50 mm, preferably 2 to 15 mm. When the length is long, uniform blending of carbon fiber and polyester or polyamide fiber becomes difficult at the time of producing the nonwoven fabric, and when it is short, the mechanical strength of the carbon fiber-containing nonwoven fabric structure is not improved. Each carbon fiber 52 has a thickness of 1 to 100 μm and a length of 1 to 50 mm. When the length is long, it becomes difficult to mix the carbon fiber and the polyester or polyamide fiber at the time of producing the nonwoven fabric, and when it is short, the mechanical strength of the carbon fiber-containing nonwoven fabric structure is not improved.

  Each fiber of the thermoplastic resin fiber 51 is made of at least one selected from the group consisting of polyester, polyamide, polypropylene, polyethylene, acrylic, polyacetal, and polycarbonate, and preferably made of polyester, polyamide, or polypropylene. .

  The blend ratio of the carbon fibers 52 to the carbon fiber-containing nonwoven fabric 2 is 20 to 70%, preferably 35 to 65% on a mass basis. When the blending ratio is small, the mechanical strength of the carbon fiber-containing nonwoven structure is not sufficient, and when it is large, the carbon fiber-containing nonwoven structure is warped during molding of the carbon fiber-containing nonwoven structure.

  The carbon fiber-containing non-woven fabric 2 is impregnated with PVB (polyvinyl butyral) resin in the gaps between the fibers on one or both sides, as will be described later in Step 1 of the production method of FIG. 6 (FIG. 5). This PVB resin is melted at the time of thermoforming the laminate of the carbon fiber-containing nonwoven fabric 2 and the thermoplastic resin sheet 3, and the adhesiveness of the laminate and the mechanical strength of the laminate structure 40 are improved.

  The laminated structure 40 in FIG. 1 forms a carbon fiber-containing nonwoven fabric structure with improved mechanical strength.

  The carbon fiber-containing nonwoven fabric laminated structure of FIGS. 1 to 3 may omit the thermoplastic resin sheet 3, and even if the carbon fiber-containing nonwoven fabric structure is constituted only by the carbon fiber nonwoven fabric 2, the carbon fiber-containing nonwoven fabric is formed by thermoforming. The same effect as the laminated structure can be obtained.

  The laminated structure 40 in FIG. 1 has an inverted basin structure with the carbon resin-containing nonwoven layer 4 as the front, but may have an inverted basin structure with the base resin layer 5 as the front.

  FIG. 6 is a diagram used to explain the apparatus for producing the carbon fiber-containing nonwoven fabric laminated structure of FIG.

  In FIG. 6, Step II to Step III are performed by the female die 10 and the male die 11 constituting the press machine, and finally, the carbon fiber-containing nonwoven fabric laminated structure is a female die by an appropriate method according to Step IV. 10 is taken out.

  6, first, the carbon fiber-containing nonwoven fabric 2 of FIG. 4 described above is prepared, and a laminate is prepared by laminating the thermoplastic resin sheet 3 on the carbon fiber-containing nonwoven fabric 2 (step 1).

  Preparation of the carbon fiber-containing non-woven fabric 2 is made by making papers of the thermoplastic resin fibers 51 and a large number of carbon fibers 2 in a liquid, and applying a solvent containing the PCB resin 53 to both surfaces of the paper-made carbon fiber-containing non-woven fabric 4. To do. The application of the solvent containing the PCB resin 53 may be only on one side of the carbon fiber-containing nonwoven fabric 2. The solvent containing the PCB resin 53 applied to at least one surface of the carbon fiber-containing nonwoven fabric 2 evaporates, and the PCB resin 53 remains in the gaps between the fibers of the carbon fiber-containing nonwoven fabric 2 (FIG. 5).

  Specifically, the PCB resin 53 is made of a polyvinyl alcohol (PVA) resin acetalized with an aldehyde, preferably a polyvinyl butyral resin acetalized with butyraldehyde.

  Specific examples of the solvent include alcohol solvents such as methanol, ethanol and isopropanol, ketone solvents such as acetone and methyl ethyl ketone, cellosolve solvents such as methyl cellosolve, amide solvents such as dimethylformamide, and ethers such as dioxane. Solvents, chlorinated hydrocarbon solvents such as methylene chloride, aromatic solvents such as xylene, dimethyl sulfoxide, or acetic acid, preferably alcohol solvents such as methanol, ethanol, isopropanol, or acetone, methyl ethyl ketone, etc. Made of ketone solvents

  Lamination of the thermoplastic resin sheet 3 to the carbon fiber-containing non-woven fabric 2 is performed by sheeting a thermoplastic resin raw material on the PCB-coated surface of the carbon fiber-containing non-woven fabric 2 with a known extrusion molding machine (T die) (FIG. 5). The thickness of the thermoplastic resin sheet 3 is 0.03 to 2.0 mm.

  Furthermore, in the process II of FIG. 6, the said laminated body is mounted on the female metal mold | die 10 (fixed metal mold | die) of a press machine by making the carbon fiber containing nonwoven fabric 2 into a table | surface. This laminated body may be cut into a predetermined shape in advance.

  Next, in step III, the male die 11 (movable die) of the press machine is moved toward the female die 10 so as to push the laminated body placed in step II into the female die 10. Simultaneously, the said laminated body is heated with each heating apparatus 61,62 incorporated in the female metal mold | die 10 and the male metal mold | die 11 of a press machine. Thereby, the said laminated body is heat-molded in the shape prescribed | regulated with the female metal mold | die 10 and the male metal mold | die 11. FIG.

  Finally, in step IV, the male mold 12 is separated from the female mold 10 and the thermoformed laminated structure 40 is taken out. At this time, deburring may be performed by cutting the periphery of the laminated structure 40 with a laser cutter or a cutting die (cutting unit).

  According to the method for producing a carbon fiber-containing nonwoven fabric laminate structure in FIG. 6, a carbon fiber-containing nonwoven fabric laminate structure with improved mechanical strength can be produced.

  In the manufacturing method of FIG. 6, you may abbreviate | omit the thermoplastic resin sheet 3 among the said laminated bodies.

  The manufacturing method of the carbon fiber-containing nonwoven fabric laminated structure in FIG. 6 has an inverted basin structure in which the laminated structure 40 has the thermoplastic resin sheet 3 as a table, and this laminated structure 40 has the carbonized fiber-containing nonwoven fabric 2 as a table. It may be an inverted basin structure.

  In the embodiment of the present invention, the laminated structure 40 is described only as a general structure. However, as an applied technical field of the embodiment of the present invention, miscellaneous goods including containers and stationary, mobile phones, and the like. And housings for electronic devices and home appliances including notebook computers, housings for interior and exterior products of buildings and automobiles, interior housings for aircraft, railway vehicles, and ships.

2 Carbon fiber-containing nonwoven fabric 3 Thermoplastic resin sheet 10 Female die 11 Male die 40 Carbon fiber-containing nonwoven fabric laminated structure 41 Projection portion 42 Opening portion 51 Thermoplastic resin fiber 52 Carbon fiber 53 PCB resin 61, 62 Heating device

Claims (13)

  A carbon fiber-containing non-woven fabric comprising a carbon fiber-containing non-woven fabric containing a thermoplastic resin fiber and a large number of carbon fibers and having a gap between the fibers impregnated with a PCB resin, wherein the carbon fiber-containing non-woven fabric is thermoformed. Construction.   The ratio of the said carbon fiber with respect to the said carbon fiber containing nonwoven fabric is 20 to 70% on a mass basis, The carbon fiber containing nonwoven fabric structure of Claim 1 characterized by the above-mentioned.   The carbon fiber-containing nonwoven fabric structure according to claim 1 or 2, wherein the carbon fiber has a length of 1 to 15 mm.   The said thermoplastic resin fiber is 1-15 mm in length, The carbon fiber containing nonwoven fabric structure of any one of Claim 1 to 3 characterized by the above-mentioned.   5. The thermoplastic resin fiber according to claim 1, wherein the thermoplastic resin fiber includes at least one selected from the group consisting of polyester, polyamide, polypropylene, polyethylene, acrylic, polyacetal, and polycarbonate. Carbon fiber-containing nonwoven fabric structure.   It comprises a laminate of a carbon fiber-containing non-woven fabric and a thermoplastic resin sheet containing a thermoplastic resin fiber and a large number of carbon fibers, and a gap between each fiber is impregnated with a PCB resin, and the laminate is thermoformed. A carbon fiber-containing nonwoven fabric laminated structure.   The ratio of the said carbon fiber with respect to the said carbon fiber containing nonwoven fabric is 20 to 70% on a mass basis, The carbon fiber containing nonwoven fabric structure of Claim 6 characterized by the above-mentioned.   The carbon fiber-containing nonwoven fabric laminated structure according to claim 7, wherein the carbon fiber has a length of 1 to 15 mm.   The carbon fiber-containing nonwoven fabric laminate structure according to claim 7 or 8, wherein the thermoplastic resin fibers have a length of 1 to 15 mm.   10. The thermoplastic resin fiber according to claim 7, wherein the thermoplastic resin fiber includes at least one selected from the group consisting of polyester, polyamide, polypropylene, polyethylene, acrylic, polyacetal, and polycarbonate. Carbon fiber-containing nonwoven fabric laminated structure.   The thermoplastic resin sheet is a sheet made of a thermoplastic resin, and this thermoplastic resin is a polyolefin resin such as polyethylene and polypropylene, a polyester resin such as polyethylene terephthalate, a polyamide resin such as nylon, and a polymethacrylate such as polymethyl methacrylate. The acrylate resin, the polystyrene resin, and the polycarbonate resin, and may be made of a copolymer such as acrylonitrile-butadiene-styrene (ABS resin). Carbon fiber-containing nonwoven fabric laminated structure.   A method for producing a carbon fiber-containing nonwoven fabric structure comprising a thermoplastic resin fiber and a large number of carbon fibers, wherein the carbon fiber-containing nonwoven fabric is prepared by papermaking the thermoplastic resin fibers and the numerous carbon fibers in a liquid. A paper making process, an impregnation process in which a solvent containing PCB resin is applied to at least one surface of the paper-made carbon fiber-containing non-woven fabric to impregnate the PCB resin with a gap between each fiber of the carbon fiber-containing non-woven fabric, and A method for producing a carbon fiber-containing nonwoven fabric structure, comprising: a thermoforming step of thermoforming a carbon fiber-containing nonwoven fabric impregnated with PCB resin.   A method for producing a carbon fiber-containing nonwoven fabric laminated structure of a carbon fiber-containing nonwoven fabric comprising a thermoplastic resin fiber and a large number of carbon fibers, wherein the thermoplastic resin fibers and the numerous carbon fibers are made in paper in a liquid. A paper making process for preparing a carbon fiber-containing non-woven fabric, and a solvent containing PCB resin is applied to at least one surface of the paper-made carbon fiber-containing non-woven fabric, and the PCB resin is impregnated in the gaps of each fiber of the carbon fiber-containing non-woven fabric. An impregnation step, a laminating step of sheeting a thermoplastic resin sheet on at least one surface of the carbon fiber-containing non-woven fabric impregnated with PCB, and heating for thermoforming the carbon fiber-containing non-woven fabric laminated with the thermoplastic resin sheet A method for producing a carbon fiber-containing nonwoven fabric laminate structure, comprising: a molding step.

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