JP3098478B2 - Manufacturing method of carbon fiber composite molded product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a carbon fiber composite molded article that is lightweight, has excellent strength, rigidity, dimensional stability, and durability, and has a characteristic anisotropic gloss.

[0002]

2. Description of the Related Art Carbon fiber composite materials are used for aircraft, automobiles, sports, leisure and various other industrial applications because of their characteristics of being lightweight and having high strength. On the other hand, the carbon fiber composite material has a characteristic anisotropic luster due to the orientation of the carbon fiber bundle constituting the carbon fiber composite material, and gives a deep and solid appearance by applying a treatment such as painting to the surface, Further, it has characteristics such as conductivity, X-ray transparency, and electromagnetic wave shielding properties.

[0003]

SUMMARY OF THE INVENTION The present invention provides a method for easily and efficiently producing a carbon fiber composite molded article having excellent appearance and physical properties using a carbon fiber composite material having such properties. It is.

[0004]

That is, the first aspect of the present invention is as follows.
The gist is composed of continuous carbon fiber and has a thickness of 0.01 to
The thickness of the carbon fiber composite material plate of 2.0 mm
A method for producing a carbon fiber composite molded article characterized in that a thermoplastic resin is injection-molded so as to have a thickness of 30 mm and bonded and integrated, and a second point is that a thickness is formed of two continuous carbon fibers. A carbon fiber composite molded product characterized by injection-molding a thermoplastic resin in the middle of a carbon fiber composite material plate having a thickness of 0.01 to 2.0 mm so as to have a thickness of 0.01 to 30 mm and joining and integrating the thermoplastic resin. Recipe.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION As a carbon fiber composite material plate, carbon fibers are aligned in one direction to form a sheet, and a known thermosetting resin (epoxy, polyester, phenol, vinyl ester, polyimide, etc.) and a known resin are used. A carbon fiber composite material plate obtained by appropriately laminating a unidirectional prepreg impregnated with a thermoplastic resin (nylon, ABS, polycarbonate, acrylic, or the like) and heating and pressing the resin as a representative example (Japanese Patent Application Hei 2-418525,
Nos. 4-32344 and 4-32345).

Further, a woven fabric or a knitted fabric made of carbon fibers is appropriately impregnated with a thermosetting resin or a thermoplastic resin by a known method in place of the one-way prepreg, laminated as necessary, and laminated by heating and pressing. Carbon fiber composite boards of 0.01-2.0 mm are also used.

The thickness of the carbon fiber composite material plate used in the present invention is 0.01 to 2.0 mm. In the case of ordinary carbon fiber filaments having a diameter of 5 to 10 μm, it is difficult to produce a composite material plate or a film having a thickness of less than 0.01 mm. It is not preferable because bending and bending deformations required for putting in the mold are poor.

In the meantime, according to the gist of the present invention, glass fibers, aramid fibers, and other organic or inorganic fibers may be used in combination as a hybrid when forming the carbon fiber composite material. It is also possible to positively use a hybrid material in order to improve the handleability.

The thermoplastic resin forming the resin layer on the surface of the carbon fiber composite material plate or in the middle of the two carbon fiber composite material plates may be nylon, ABS, polycarbonate, acrylic, or any other resin that can be injection molded. Any known thermoplastic resin or reinforced thermoplastic resin can be appropriately selected and used in consideration of the adhesion to the matrix resin, the deterioration temperature, and the like. The thickness of the resin layer, that is, the ratio of the thickness to the carbon fiber composite material plate, is determined from the balance between the performance demonstrating efficiency and the material cost.

In order to obtain a lightweight and highly rigid material,
It is effective to form a sandwich structure by forming a thermoplastic resin layer on an intermediate layer of two carbon fiber composite material plates.
In order to make use of the characteristic anisotropic luster of carbon fibers in the appearance of a molded product, it is effective to use a carbon fiber composite material for the outer layer. By these methods, lightweight, high-performance, and good-looking molded articles can be obtained.

Further, in the molded article having the carbon fiber composite material plate exposed on the surface, the resin forming the matrix and the resin layer of the carbon fiber composite material plate is made of an acrylic resin, so that the carbon fiber composite plate has a unique depth to carbon fiber. A certain luster and pattern appear more vividly and exhibit a design effect.

Although the carbon fiber composite molded article of the present invention can be produced by using an existing injection molding machine, a large molded article can be molded by using an injection press. The adhesion between the material plate and the resin layer becomes strong.

[0013]

EXAMPLES The present invention will be described more specifically below with reference to examples.

[Example 1] Carbon fiber tow (Pyrofil TR4 manufactured by Mitsubishi Rayon Co., Ltd.) bundled with 3000 carbon fibers
0) is impregnated with an acrylic resin into a woven carbon fiber woven fabric (12.5 lines / inch for both processes) and 0.3 mm
A thick sheet was formed.

Next, this sheet-shaped material is 95 × 520 mm
, Set on the bottom of a dish mold, and injection-molded polymethyl methacrylate (Acrylite VH manufactured by Mitsubishi Rayon Co., Ltd.) at a cylinder temperature of 250 ° C. and a mold temperature of 60 ° C. to form a carbon fiber composite material on the outer layer. A 3 mm thick molded article with layers was obtained.

The test piece cut out from this was subjected to AS
When a bending test according to TM D-790 was performed,
Excellent characteristics are shown in Table 1. In addition, the surface had a high-grade profound feeling peculiar to the carbon fiber composite material, and could be effectively used for daily necessities and automobile interior parts.

[Example 2] A carbon fiber cloth prepreg using an epoxy resin as a matrix resin (TR3110 340 manufactured by Mitsubishi Rayon Co., Ltd.) was used. A 3 mm thick molded article having a fiber composite material layer was obtained.

The test piece cut out from this was subjected to AS
When a bending test was performed in accordance with TMD-790, excellent characteristics were shown in Table 1.

Example 3 The resin to be injected was carbon fiber reinforced polycarbonate resin (Pyrofil Pellets PC-C-20 manufactured by Mitsubishi Rayon Co., Ltd.) and the average cylinder temperature was 3
A molded product having a thickness of 3 mm was obtained by performing the same operation as in Example 1 except that the temperature was changed to 00 ° C and the mold temperature was changed to 80 ° C.

The test piece cut out from this was subjected to AS
When a bending test was performed in accordance with TMD-790, excellent characteristics were shown in Table 1.

[Embodiment 4] The cut size of the sheet is 145 ×
A 3 mm-thick molded product having a carbon fiber composite material layer on the tray wall was obtained in the same manner as in Example 1 except that the thickness was changed to 520 mm. When the cross section was observed, it was a good molded product without any defect such as buckling in the carbon fiber at the corner.

[Embodiment 5] In the portion corresponding to the gate portion, 13
The same operation as in Example 1 was carried out except that the sheet with the hole of mmφ and the sheet without the hole were set in a mold by superimposing the sheet, and the sheet having the carbon fiber composite material layer on both surfaces of the resin layer was 3 mm.
A thick sandwich molded product was obtained.

The test piece cut out from this was subjected to AS
When a bending test was performed according to TMD-790, particularly excellent characteristics were shown in Table 1. In addition, the surface had a high-grade profound feeling peculiar to the carbon fiber composite material, and could be effectively used for daily necessities and automobile interior parts.

[0024]

[Table 1]

[0025]

According to the present invention configured as described above,
A carbon fiber composite molded product having excellent appearance and physical properties can be obtained extremely easily and efficiently.

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 45/00-45/84

Claims (5)

(57) [Claims] 1. It has flexibility made of continuous carbon fiber.
A thermoplastic resin injection molded on a surface of a carbon fiber composite material plate having a thickness of 0.01 to 2.0 mm so as to have a thickness of 0.01 to 30 mm, and bonded and integrated. Manufacturing method for composite molded products. 2. A flexible sheet made of two continuous carbon fibers, having a thickness of 0.01 to 2.0 mm, and being heated to a thickness of 0.01 to 30 mm in the middle of a carbon fiber composite material plate. A method for producing a carbon fiber composite molded article, comprising injection-molding a plastic resin and bonding and integrating the same. Wherein the matrix resin in the carbon fiber composite material plate according to claim 1 or 2 Preparation of carbon fiber composite molded article, wherein the acrylic resin. 4. A resin forming the thermoplastic resin layer method according to claim 1 or 2, wherein the carbon fiber composite moldings is an acrylic resin. 5. A method according to claim 1 1 or 2 Preparation of carbon fiber composite moldings according performing injection molding by injection press.