JP5250898B2 - Thermoplastic resin reinforced sheet material, production method thereof, and thermoplastic resin multilayer reinforced sheet material - Google Patents

Description

The present invention relates to a sheet material suitable for obtaining a molded article of a thermoplastic resin composite material having a three-dimensional shape, and more specifically, to a reinforcing fiber sheet material in which reinforcing fibers such as carbon fibers are arranged in a sheet shape. Thermoplastic resin reinforcing sheet material to which thermoplastic resin sheet material is adhered, manufacturing method thereof, and thermoplastic resin multilayer reinforcing sheet material obtained by laminating and integrating a plurality of obtained thermoplastic resin reinforcing sheet materials It is.

Fiber reinforced composite material is a combination of fiber material and matrix material, and it is lightweight, rigid and capable of various functional designs. It is widely used in aerospace field, transportation field, civil engineering field, exercise equipment field, etc. Used in the field. Currently, fiber reinforced plastic (FRP) in which a reinforcing fiber material such as carbon fiber or glass fiber is combined with a thermosetting resin material has become the mainstream. However, it is considered that the development of molded products using a thermoplastic resin material as a matrix resin will increase in the future due to advantages such as recyclability, short-time moldability, and improved impact resistance of molded products.

On the other hand, when obtaining molded products, attention is paid to molded products and molding methods using multiaxial reinforcing sheet materials laminated so that the reinforcement direction of the reinforcing fiber material is multiaxial in order to facilitate molding and reduce molding costs. Has been.

From this, a sheet material combining a reinforcing fiber material and a thermoplastic resin material, in particular, a sheet material combining a multiaxial reinforcing sheet material in which reinforcing fiber materials are laminated in multiple axes and a thermoplastic resin material, and the sheet High-quality, short-time and low-cost production of molded products is expected.

As a sheet material combined with a reinforcing fiber material and a thermoplastic resin material, for example, in Patent Document 1, a fabric in which a thermoplastic fiber is non-woven in a reinforcing fiber sheet in which a plurality of reinforcing fiber bundles are aligned in one direction is used. A thermoplastic prepreg sheet or semi-prepreg is obtained by melting the thermoplastic resin nonwoven fabric and impregnating or semi-impregnating the thermoplastic resin into the reinforcing fiber bundle by applying pressure while heating the laminated thermoplastic resin nonwoven fabric. It is described to obtain a sheet.

As a sheet material in which the reinforcement direction of the reinforcing fiber material is oriented in multiple axes and combined with the thermoplastic resin material, for example, in Patent Document 2, a plurality of reinforcing fiber yarns are arranged in parallel in a sheet shape to form a layer structure. None, there is described a reinforcing multiaxial stitched fabric in which at least two of the layers are cross-laminated to form a laminated body, and the laminated body is stitched and integrated with a low-melting polymer yarn. Then, the reinforcing multiaxial stitch fabric is impregnated with a thermosetting resin or a thermoplastic resin, and is heat-molded to a temperature higher than the melting point of the low-melting polymer yarn, whereby the FRP having excellent surface smoothness in which the stitch yarn structure disappears. It is described that a molded product is obtained.

In Patent Document 3, a reinforced prepreg sheet impregnated with a thermoplastic resin is arranged in the longitudinal direction, and another thermoplastic resin prepreg sheet is spirally wound around the thermoplastic resin prepreg sheet, thereby reinforcing the fibers in three directions. A sheet and its manufacturing method are described. In addition, a fiber reinforced sheet in which a thermoplastic resin prepreg sheet is arranged in the 90-degree direction of the sheet longitudinal direction and the four directions are reinforced with respect to the fiber reinforced sheet reinforced in three directions, and a manufacturing method thereof are described. Yes.

In Patent Document 4, a unidirectional wrap having binding properties is formed from a hybrid yarn composed of reinforcing filaments and organic material filaments, and the wrap is folded in the transverse direction with respect to the moving direction and then reinforced by heating or heating and pressing. A method and apparatus is described for producing a composite sheet that is fiber reinforced in a multiaxial direction by fixing the yarn / organic material. The organic material is a thermoplastic resin that works as a base material, and it is described that the composite sheet is provided so that a composite material molded product having a complicated shape can be manufactured.

In Patent Document 5, a reinforcing fiber sheet is prepared from a reinforcing fiber bundle that is spread and widened so that the width per 1000 single yarns is 1.3 mm or more, and the reinforcing fiber sheet is inclined so that the reinforcing direction is inclined from the reinforcing fiber sheet. The multiaxial laminated reinforcing fiber sheet and the method for producing the multiaxial laminated reinforcing fiber sheet which are laminated and joined by thermal adhesive bonding or stitching with yarn or fibers having a reinforcing effect are described. Has been. And when laminating | stacking a gradient reinforcement fiber sheet, the method of including the matrix layer by a thermoplastic resin between layers is described.

In Patent Document 6, a prepreg tape in which a reinforced fiber is impregnated with a thermoplastic resin is laminated in multiple axes, and a multiaxial laminated sheet is manufactured by stitching and integrated, and then the multiaxial laminated sheet is cut or laminated. Thus, a method for forming a fiber reinforced thermoplastic composite material is described. It is described that since the reinforcing fiber is impregnated with the thermoplastic resin in advance, the molding can be performed in a relatively short time, and the molding cycle can be shortened.

Japanese Patent Laid-Open No. 2003-165851 JP 2002-227066 A JP 2006-224543 A Special table 2004-530053 gazette JP 2006-130698 A JP 2007-1089 A International Publication No. 2005/002819 Pamphlet JP 2005-029912 A

Kawamasa Kazumasa et al., “Thermoplastic resin impregnation simulation for developing thermoplastic resin prepreg apparatus”, Fukui Industrial Technology Center 2000 Research Report, No. 17

In Patent Document 1 described above, a prepreg sheet or a semi-prepreg sheet in which a fiber bundle is impregnated with a thermoplastic resin is obtained using a thermoplastic resin in a nonwoven fabric state. When the thermoplastic resin is melted and impregnated or semi-impregnated in the fiber bundle, even if the thickness of the prepreg sheet is thin, the draping property is deteriorated, and it is possible to adapt the prepreg sheet to a molding die having a three-dimensional shape. difficult. In addition, when producing the prepreg sheet or semi-prepreg sheet, it is necessary to heat and press the melt to impregnate the fiber bundle and impregnate the fiber bundle, and the molding apparatus cannot be enlarged and the molding speed cannot be increased. There are issues such as.

In Patent Document 2, in order to obtain an FRP molded product by impregnating a reinforcing multiaxial stitched fabric with a resin, a reinforcing fiber forming the reinforcing multiaxial stitched fabric when impregnated with a thermosetting resin having excellent flow characteristics It is easy to impregnate the resin between the fibers of the yarn, but when impregnating a thermoplastic resin that has a high resin viscosity at the time of melting and poor flow characteristics, impregnate the resin between the fibers of the reinforcing fiber yarn It becomes very difficult. For this reason, the thermoplastic resin composite material molded product using the reinforcing multi-axis stitched fabric requires a longer time for resin impregnation to obtain a molded product, resulting in a higher molding cost, and a resin non-impregnated portion, that is, a void (void) ) Can be increased and the mechanical properties are deteriorated.

In Patent Document 3 and Patent Document 6, a prepreg sheet impregnated with a thermoplastic resin and a prepreg tape are used to obtain a multiaxially reinforced sheet, but a prepreg sheet and a prepreg impregnated with a thermoplastic fiber material in a reinforcing fiber bundle. Since the tape is rigid, the sheet and the sheet in which the tape is oriented in multiple axes lack drapeability, and there is a problem that it is difficult to adapt it to a molding die having a three-dimensional shape. In addition, in order to obtain the thermoplastic resin prepreg sheet and tape, a step of manufacturing a prepreg sheet by impregnating the thermoplastic fiber into the reinforcing fiber bundle is necessary, but impregnating the thermoplastic fiber into the reinforcing fiber bundle. Is not easy and requires manufacturing time, and there is a problem that the cost of finally obtaining an FRP molded product increases.

In Patent Document 4, a hybrid yarn composed of reinforcing filaments and organic material filaments is used. However, it is difficult to uniformly mix reinforcing filaments and organic material filaments, and the resulting composite material molded product is highly likely to be a voided molded product in which fibers are not uniformly dispersed. Moreover, since the blended yarn is manufactured one by one, the cost of manufacturing the blended yarn is increased, and there is a problem that the cost of the obtained composite material molded product is increased.

In Patent Document 5, a reinforcing fiber sheet is prepared by bonding and integrating a plurality of spread fiber reinforced fiber bundles with a thread, an adhesive fiber web, or a porous adhesive layer having an adhesive function. In order to bond and unify a plurality of spread fiber reinforced fiber bundles only with a yarn having an adhesive function, an adhesive fiber web, or a porous adhesive layer, a certain amount of yarn or adhesive amount is required. On the contrary, when the amount of the yarn having the adhesive function or the adhesive fiber web or the porous adhesive layer is small, it is difficult to bond and integrate the plurality of reinforcing fiber bundles. The reinforcing fiber bundle of the book is easy to disperse, and the reinforcing fiber bundle that has been spread and widened converges, so that the form as a reinforcing fiber sheet cannot be maintained. In addition, in the Example, the uniaxial reinforcement fiber sheet | seat which united and integrated the carbon fiber bundle | flux expanded and expanded to 31 mm by the fiber web of 4 g / m < ² > of fabric weight which consists of hot-melt-adhesive fiber is created. . Since the amount of carbon fiber used is about 24.5 g / m ² , the amount of hot melt adhesive used is about 16.3% of the amount of carbon fiber used.

And in patent document 5, after obtaining the inclination reinforcement fiber sheet from a reinforcement fiber sheet, the said inclination reinforcement fiber sheet and a thermoplastic resin matrix layer are laminated | stacked, it joins by a thermal adhesive, or the stitch by the thread | yarn or the fiber which has a reinforcement effect The multiaxial laminated reinforcing fiber sheet for obtaining a molded product of a thermoplastic resin composite material is obtained by joining and integrating with each other. In order to use a yarn or adhesive fiber web or porous adhesive layer having a certain amount of adhesive function in the step of creating a reinforcing fiber sheet, these adhesives must be mixed with the thermoplastic resin as a matrix. Therefore, there is a possibility that the mechanical characteristics of the composite material molded article are deteriorated. In addition, stitching with yarns and fibers having a reinforcing effect is obtained by laminating a gradient reinforcing fiber sheet and a thermoplastic resin matrix layer when a multi-axis laminated reinforcing fiber sheet is heat-press molded to obtain a composite material molded product. Since the thickness that has been reduced is reduced by the impregnation of the thermoplastic resin into the reinforcing fiber bundle, the yarn or fibers having a reinforcing effect sag and the reinforcing fiber may be prevented from straightening. In addition, the slack yarns and fibers do not reinforce in the thickness direction of the composite material molded product, but conversely exist as different kinds of materials and cause a decrease in mechanical properties in the composite material molded product.

As a result of earnest research and development, the inventor of the present invention, as described in Non-Patent Document 1, as the thickness of the fiber bundle becomes thinner, even in a high-viscosity thermoplastic resin, It has been confirmed that the resin can be impregnated therein, and, as described in Patent Document 7, a fiber opening technique for manufacturing a wide fiber bundle with a wide and thin fiber sheet with a low material cost. Is developing. Furthermore, Patent Document 8 develops a method and an apparatus for producing a thermoplastic resin prepreg sheet using a thermoplastic resin sheet by aligning a plurality of spread yarns in the width direction without gaps.

Therefore, the present invention is based on such knowledge and fiber opening technology, and uses a thermoplastic resin having excellent recyclability, impact resistance, etc. as a matrix. Plastic resin reinforced sheet material, method for producing the thermoplastic resin reinforced sheet material in a short time efficiently and at low cost, and high quality, excellent mechanical properties and draping properties, and low cost thermoplasticity An object of the present invention is to provide a resin multilayer reinforcing sheet material.

The thermoplastic resin reinforcing sheet material according to the present invention includes a reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction and formed into a sheet shape, and heat that becomes a matrix resin attached to the reinforcing fiber sheet material. A thermoplastic resin sheet material and an adhesive that is melted or softened at a temperature lower than the melting temperature of the thermoplastic resin sheet material and adhered to one or both surfaces of at least one of the reinforcing fiber sheet material and the thermoplastic resin sheet material The reinforcing fiber sheet material is adhered to both surfaces of the thermoplastic resin sheet material so that the directions in which the reinforcing fibers are aligned are the same direction . Further, the reinforcing fiber sheet material and the thermoplastic resin sheet material are bonded by the adhesive thermoplastic resin material, and the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material. Further, the reinforcing fiber sheet material and the thermoplastic resin sheet material are thermoplastic resin reinforcing sheet materials bonded by the adhesive thermoplastic resin material, and one or both surfaces of the thermoplastic resin reinforcing sheet material In the thermoplastic resin reinforced sheet material to which the adhesive thermoplastic resin material is adhered, the adhesion amount per unit area of the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material However, it differs from the adhesion amount per unit area of the said thermoplastic resin material for adhesion adhere | attached on the one or both surfaces of the said thermoplastic resin reinforcement sheet material. Further, the reinforcing fiber sheet material and the thermoplastic resin sheet material are thermoplastic resin reinforcing sheet materials bonded by the adhesive thermoplastic resin material, and one or both surfaces of the thermoplastic resin reinforcing sheet material In the thermoplastic resin reinforced sheet material to which the adhesive thermoplastic resin material is attached, the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material is the thermoplastic resin reinforced material. It is characterized by being a resin different from the adhesive thermoplastic resin material attached to one or both sides of the sheet material. Further, the thermoplastic resin reinforced sheet material is adhered to the release sheet material by the adhesive thermoplastic resin material, and the release sheet material is integrated with the thermoplastic resin reinforced sheet material. . Further, the reinforcing fiber sheet material is characterized in that a cross-sectional thickness of the reinforcing fiber sheet material is set within 10 times the diameter of the reinforcing fiber. Furthermore, the adhesion amount per unit area of the thermoplastic resin material for bonding is within 3% of the weight per unit area of the reinforcing fiber sheet material.

The thermoplastic resin multilayer reinforcing sheet material according to the present invention is characterized in that only a plurality of the above thermoplastic resin reinforcing sheet materials are laminated and integrated. Furthermore, the thermoplastic resin reinforcing sheet material is laminated so that the reinforcing fiber sheet material in which the reinforcing fibers are aligned in the same direction is multiaxial. Furthermore, the thermoplastic resin material for bonding is heated and melted or softened by heating, and the thermoplastic resin reinforced sheet material laminated in plural is bonded and integrated. Further, the thermoplastic resin material for bonding is partially heated and melted or softened by heating, and a plurality of laminated thermoplastic resin reinforcing sheet materials are partially bonded and integrated. Furthermore, a plurality of laminated thermoplastic resin reinforcing sheet materials are stitched and integrated by stitching with a thermoplastic resin fiber bundle for integration which is the same material as the thermoplastic resin sheet material.

A method for producing a thermoplastic resin reinforced sheet material according to the present invention includes a sheet forming step of creating a sheet-like reinforcing fiber sheet material by aligning a plurality of reinforcing fibers in a predetermined direction, and the reinforcing fiber sheet material as a matrix resin. One side of the sheet material to which the reinforcing fiber sheet material and the thermoplastic resin sheet material are adhered after being attached so that the direction in which the reinforcing fibers are aligned is the same direction on both surfaces of the thermoplastic resin sheet material An adhesion step in which an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material is adhered to both surfaces. Another method for producing a thermoplastic resin reinforced sheet material according to the present invention includes a sheet forming step of creating a sheet-like reinforcing fiber sheet material by aligning a plurality of reinforcing fibers in a predetermined direction, and the reinforcing fiber sheet material and the matrix. An adhesion step of attaching an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material to at least one or both surfaces of the thermoplastic resin sheet material to be a resin; and The reinforcing fiber sheet material is overlapped on both surfaces of the thermoplastic resin sheet material so that the direction in which the reinforcing fibers are aligned is the same direction and the adhesive thermoplastic resin material exists between the layers of the both sheet materials, The reinforcing fiber sheet is heated or heated and pressed at a temperature lower than the temperature at which the thermoplastic resin sheet material melts to melt or soften the adhesive thermoplastic resin material. A bonding step to attach the timber to the thermoplastic resin sheet material, characterized in that it comprises a. In the above method for producing a thermoplastic resin reinforced sheet material, in the sheet forming step, as the reinforcing fiber sheet material, a plurality of reinforcing fibers are aligned in a predetermined direction and the cross-sectional thickness thereof is 10 times the diameter of the reinforcing fibers. It is characterized in that it is formed in a sheet shape within. Further, in the sheet forming step, as the reinforcing fiber sheet material, a reinforcing fiber bundle in which a plurality of long-fiber reinforcing fibers are gathered is continuously widened in the width direction, and a widened and thinned open yarn is used. It is characterized by forming. Further, the adhesive fiber sheet material and the release sheet material are laminated so that the adhesive thermoplastic resin material exists, and heated or heated at a temperature lower than the temperature at which the thermoplastic resin sheet material melts. The adhesive thermoplastic resin material is melted or softened to adhere the reinforcing fiber sheet material and the release sheet material. Further, a release sheet material is superposed on the thermoplastic resin reinforced sheet material so that the adhesive thermoplastic resin material is present between the two sheet materials, and is lower than a temperature at which the thermoplastic resin sheet material melts. Heating or pressurizing at a temperature to melt or soften the adhesive thermoplastic resin material to adhere the thermoplastic resin reinforcing sheet material and the release sheet material.

The method for producing a thermoplastic resin multilayer reinforcing sheet material according to the present invention includes a laminating step in which at least one thermoplastic resin reinforcing sheet material is superposed in the thickness direction, and a plurality of the thermoplastic resin reinforcing sheets laminated. And an integration step of integrating the materials. Further, in the laminating step, the thermoplastic resin reinforcing sheet material is laminated and laminated so that directions in which the reinforcing fibers are aligned are multiaxial. Furthermore, in the integration step, the laminated thermoplastic resin reinforcing sheet material is heated or heated and pressurized at a temperature at which the adhesive thermoplastic resin material melts or softens, and is laminated. The materials are bonded and integrated by the thermoplastic resin material for bonding. Further, in the integration step, the laminated thermoplastic resin reinforced sheet material is partially heated or heated and pressurized at a temperature at which the adhesive thermoplastic resin material melts or softens, and the laminated thermoplastic resin material is laminated. The resin reinforcing sheet material is partly bonded and integrated with the adhesive thermoplastic resin material. Furthermore, in the integration step, the laminated thermoplastic resin reinforcing sheet material is stitched and integrated by stitching with the thermoplastic resin fiber bundle for integration which is the same material as the thermoplastic resin sheet material. And

In the thermoplastic resin reinforced sheet material according to the present invention, a reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction and a sheet-like thermoplastic resin sheet material serving as a matrix resin are attached. It is a sheet material, and has a configuration in which an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material adheres to one surface or both surfaces of the sheet material. From this, when the thermoplastic resin reinforced sheet material is cut and laminated in the required direction, the laminated thermoplastic resin is heated or heated and pressurized at a temperature at which the adhesive thermoplastic resin material melts or softens. The respective layers of the resin reinforced sheet material can be integrated by bonding with an adhesive thermoplastic resin material. In other words, it becomes easier to handle the laminated thermoplastic resin reinforced sheet material, and when installing in a mold for molding, lamination is performed while maintaining the reinforcing fiber reinforcement direction, the reinforcing fiber alignment state, etc. The made thermoplastic resin reinforcing sheet material can be easily installed in the mold for molding.

In addition, since the reinforcing fiber sheet material is attached to both sides of the thermoplastic resin sheet material used as the matrix resin, the same material sheet material is attached to both sides, so the thermoplastic resin reinforcing sheet material is either one side. Therefore, the flat shape can be maintained without being deformed by curling.

And when the blending ratio of both sheet materials is set to a predetermined value, the reinforcing fiber sheet material can be attached to both sides of the thermoplastic resin sheet material by half so that the thickness of the reinforcing fiber sheet material can be set thin. When the thermoplastic resin is impregnated in the fiber sheet material, the impregnation distance is shortened. Therefore, it is possible to obtain a molded product of good quality in which the voids such as voids are further reduced in a shorter time.

When the thermoplastic resin reinforced sheet material is made thinner, it is easier to reduce the thickness of the reinforcing fiber sheet material than the thermoplastic resin sheet material. By attaching the sheet material, the thermoplastic resin-reinforced sheet material can be made thinner.

Further, in the thermoplastic resin reinforced sheet material according to the present invention, the thermoplastic resin sheet material is adhered to one side or both sides of the reinforcing fiber sheet material by an adhesive thermoplastic resin material. For this reason, the thermoplastic resin sheet material reliably adheres to the reinforcing fiber sheet material, the form as the thermoplastic resin reinforced sheet material is maintained, and the handling becomes easy. Moreover, the aligned state of the reinforcing fibers constituting the reinforcing fiber sheet material can be maintained.

Furthermore, the thermoplastic resin reinforced sheet material is different from the prepreg sheet in which the thermoplastic resin material is impregnated between the reinforcing fibers because the reinforcing fiber sheet material is attached to the thermoplastic resin sheet material that becomes the matrix resin. Excellent drapeability. By using a narrow thermoplastic resin reinforced sheet material, the drapeability as a sheet is further improved, and the adaptability to a three-dimensional shape is improved.

Furthermore, the thermoplastic resin reinforced sheet material adheres to the adhesion amount per unit area of the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material and to one or both surfaces of the thermoplastic resin reinforced sheet material. The adhesion amount per unit area of the adhesive thermoplastic resin material is different, or one side of the adhesive thermoplastic resin material and the thermoplastic resin reinforcing sheet material for adhering the reinforcing fiber sheet material and the thermoplastic resin sheet material or Because the adhesive thermoplastic resin material that is attached to both sides is different, the adhesive layer between the reinforcing fiber sheet material and the thermoplastic resin sheet material, and the thermoplastic resin multilayer that changes the adhesive force between the thermoplastic resin reinforced sheet materials A reinforcing sheet material can be obtained. Thereby, the shift | offset | difference between each lamination | stacking of a thermoplastic resin reinforcement sheet material is realizable, making a reinforcement fiber sheet material adhere to a thermoplastic resin sheet material, and maintaining the state which the reinforcement fiber was gathered, and the dispersion state. In other words, a thermoplastic multi-layer reinforcing sheet material that is easy to handle with a plurality of thermoplastic resin reinforcing sheet materials bonded and integrated, but the thermoplastic multi-layer reinforcing sheet material is placed in a mold for molding. In this case, it is possible to adapt to the mold shape while shifting the layers of the thermoplastic resin reinforcing sheet material without damaging the alignment state and dispersion state of the reinforcing fibers in the curved surface shape part etc. in the mold. To obtain a thermoplastic resin multilayer reinforcing sheet material having further improved drapeability to a desired shape.

Further, since the thermoplastic resin reinforced sheet material is integrated with the release sheet material, the form as the thermoplastic resin reinforced sheet material is more stable and the handling is more excellent. Moreover, the aligned state of the reinforcing fibers constituting the reinforcing fiber sheet material can be maintained. Furthermore, when cutting the thermoplastic resin reinforcing sheet material, it is possible to perform cutting while further suppressing the orientation disorder of the fibers constituting the reinforcing fiber sheet material by cutting together with the integrated release sheet material. Thereby, joining and lamination | stacking of the cut thermoplastic resin reinforcement sheet | seat material can be performed in the state which suppressed the reinforcement fiber disturbance of the cut part as much as possible, and it becomes possible to obtain a high quality composite material molded article.

Furthermore, since the thermoplastic resin reinforced sheet material has a cross-sectional thickness of the reinforced fiber sheet material configured within 10 times the diameter of the reinforced fiber, the thermoplastic resin impregnates between the reinforced fibers. For this reason, the distance that flows is shortened, and the molding process can be realized in a short time. Further, during the molding process, the disorder of the orientation of the reinforcing fibers due to the resin flow is suppressed, and the molding can be performed while maintaining the uniform dispersibility of the reinforcing fibers. And it becomes possible to mold to reduce the void (void) portion where the resin does not flow.

Furthermore, the thermoplastic resin reinforced sheet material has an adhesion amount per unit area of the adhesive thermoplastic resin material within 3% of the weight per unit area of the reinforcing fiber sheet material. The influence of the material on the mechanical and thermal properties of the resulting molded product can be greatly reduced or eliminated.

The thermoplastic resin multilayer reinforcing sheet material according to the present invention is formed by laminating a plurality of the above thermoplastic resin reinforcing sheet materials. For this reason, when a thermoplastic resin multilayer reinforcing sheet material is heated and pressed to obtain a composite material molded product, there is a thermoplastic resin sheet material that becomes a matrix (base material) adjacent to each reinforcing fiber sheet material, It becomes easy to impregnate the thermoplastic resin between the reinforcing fibers. That is, by disposing the reinforcing fiber sheet material and the thermoplastic resin sheet material in each layer, the distance that the thermoplastic resin flows between the reinforcing fibers for impregnation is shortened. A small number of molded products can be obtained.

Furthermore, the thermoplastic resin multilayer reinforcing sheet material is formed by laminating a plurality of the above thermoplastic resin reinforcing sheet materials. At this time, the thermoplastic resin reinforcing sheet material was laminated with the reinforcing direction being the same direction. In the case of a thermoplastic resin multilayer reinforced sheet material, a thick sheet material or molded product reinforced in one direction can be obtained in good quality in a short time. And in the case of the thermoplastic resin multilayer reinforcing sheet material laminated with the reinforcing direction of the thermoplastic resin reinforcing sheet material different from each other, a thick sheet material or molded product reinforced in multiple directions can be obtained with good quality in a short time. be able to.

Furthermore, the thermoplastic resin multilayer reinforcing sheet material is formed by integrating the thermoplastic resin reinforcing sheet material, which is laminated in a plurality of layers, with an adhesive thermoplastic resin material. For this reason, there is no yarn used. Therefore, the composite material molded product molded by the thermoplastic resin multilayer reinforcing sheet material becomes a molded product in which the surface smoothness and the mechanical characteristics are maintained.

Further, the thermoplastic resin multilayer reinforcing sheet material is obtained by stitching and integrating the above-mentioned laminated thermoplastic resin reinforcing sheet materials with a thermoplastic resin fiber bundle for integration which is the same material as the thermoplastic resin material. When a thermoplastic resin multilayer reinforcing sheet material is heated and pressed to obtain a composite molded product, the thermoplastic resin fiber bundle for integration also melts and is integrated with the thermoplastic resin material and exists as a base material (matrix) become. Furthermore, when the thermoplastic resin fiber bundle for integration is melted, the reinforcing fibers are easily separated and the fibers are uniformly dispersed. In other words, the yarn used for integration as in the prior art and the fiber having a reinforcing effect are present in the base material (matrix), leading to deterioration in mechanical characteristics and surface smoothness as a composite material molded product, It does not hinder the dispersion of reinforcing fibers.

The method for producing a thermoplastic resin reinforced sheet material according to the present invention includes heating or pressurizing at a temperature lower than the temperature at which the thermoplastic resin sheet material melts, and bonding the reinforced sheet material and the thermoplastic resin sheet material to the thermoplastic resin material for bonding. Adhere by. Since the heating is performed at a temperature lower than the temperature at which the thermoplastic resin sheet material melts, the shrinkage of the thermoplastic resin sheet material that may occur due to the heating does not occur, or even if it occurs, it becomes very small. For this reason, the thermoplastic resin reinforcement sheet material which maintained the straight state of the reinforcement fiber, the quality of the thermoplastic resin sheet material, etc. can be obtained.

Also, because the surface of the thermoplastic resin sheet material is smooth by the method of adhering the thermoplastic resin material for adhesion to the thermoplastic resin sheet material, a small amount of the thermoplastic resin material for adhesion is uniformly adhered to the entire sheet surface. And the adhesion between the reinforcing fiber sheet material and the thermoplastic resin sheet material can be improved.

Furthermore, heating or heating / pressing is performed at a temperature lower than the temperature at which the thermoplastic resin sheet material melts, and the reinforcing sheet material and the thermoplastic resin sheet material are adhered by the adhesive thermoplastic resin material. Since it is not necessary to melt and impregnate the thermoplastic resin sheet material between the reinforcing fibers constituting the reinforcing fiber sheet material, the equipment for heating or heating and pressurization can be reduced in size, and wide thermoplastic resin reinforcement Equipment for continuously processing sheet materials at high speed can be introduced relatively easily and at low cost. In addition, a release sheet material may be required in heating or heating and pressurization for attaching the reinforcing sheet material and the thermoplastic resin sheet material with the adhesive thermoplastic resin material. Even in this case, since the heating temperature is low, release paper or the like can be used as the release sheet material, and it is possible to obtain a wide thermoplastic resin reinforced sheet material with reduced running cost.

Furthermore, when manufacturing the thermoplastic resin reinforcing sheet material, by using the opening yarn of the reinforcing fiber bundle as the reinforcing fiber sheet material, the plurality of reinforcing fibers are aligned in a predetermined direction and the cross-sectional thickness of the reinforcing fiber bundle is adjusted. It is possible to efficiently form a sheet having a diameter within 10 times. And since the high-definition fiber bundle with a low material price can be used, low-cost production is enabled.

In the method for producing a thermoplastic resin multilayer reinforcing sheet material according to the present invention, a plurality of thermoplastic resin reinforcing sheet materials are overlapped in the thickness direction. Thereby, it is possible to arrange the reinforcing fibers and the thermoplastic resin material in each layer with high production efficiency. Further, since the thermoplastic resin reinforced sheet material has a certain width, the thermoplastic resin reinforced sheet material of each layer in the thermoplastic resin multilayer reinforced sheet material can be formed with high productivity.

Furthermore, the thermoplastic resin multilayer reinforcing sheet material is obtained by heating and melting the adhesive thermoplastic resin material and bonding and integrating the laminated thermoplastic resin reinforcing sheet materials, or the same material as the thermoplastic resin sheet material. It is obtained by a method in which a plurality of laminated thermoplastic resin reinforcing sheet materials are stitched and integrated by stitching with a thermoplastic resin fiber bundle for integration. Thereby, the lamination | stacking of the laminated thermoplastic resin reinforcement sheet material can be performed at high speed. In particular, the adhesion integration with the thermoplastic resin material for adhesion does not mean that the thermoplastic resin sheet material is melted and impregnated between the reinforcing fibers, so that the layers can be bonded and integrated in a short time.

Furthermore, in the method for producing a thermoplastic resin multilayer reinforcing sheet material according to the present invention, since the thermoplastic fiber sheet material is not impregnated into the reinforcing fiber sheet material, the drapeability of the thermoplastic resin reinforcing sheet material is maintained, and the three-dimensional shape is achieved. It is possible to obtain a multilayer or multiaxial multilayer sheet material having excellent adaptability.

It is a schematic diagram which shows the thermoplastic resin reinforcement sheet material which concerns on this invention. It is a schematic diagram which shows another thermoplastic resin reinforcement sheet material which concerns on this invention. It is a schematic diagram which shows another thermoplastic resin reinforcement sheet material which concerns on this invention. It is a schematic diagram which shows the thermoplastic resin reinforcement sheet material obtained by aligning and arranging a narrow width thermoplastic resin reinforcement sheet material in the width direction. It is a schematic diagram which shows the thermoplastic resin multilayer reinforcement sheet material which laminated | stacked and integrated the thermoplastic resin reinforcement sheet material. It is a schematic diagram which shows the thermoplastic resin multilayer reinforcement sheet material which laminated | stacked and integrated the thermoplastic resin reinforcement sheet | seat material by the thermoplastic resin fiber bundle for integration. It is explanatory drawing regarding the manufacturing method of a thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of another thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of another thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of another thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of another thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of the thermoplastic resin multilayer reinforcement sheet material by a thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the method of producing and drawing out a plurality of narrow thermoplastic resin reinforcement sheet materials from a thermoplastic resin reinforcement sheet material. It is explanatory drawing regarding the manufacturing method of the thermoplastic resin multilayer reinforcement sheet material by a narrow width thermoplastic resin reinforcement sheet material.

Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are preferable specific examples for carrying out the present invention, and thus various technical limitations are made. However, the present invention is particularly limited in the following description. Unless otherwise specified, the present invention is not limited to these forms.

FIG.1 and FIG.2 is a schematic diagram which shows a part of the thermoplastic resin reinforcement sheet material 1 regarding embodiment which concerns on this invention. The thermoplastic resin reinforcing sheet material 1 in FIG. 1 has a reinforcing fiber bundle 2t, in which a plurality of reinforcing fibers 2f are bundled by a sizing agent or the like, formed in a single-sided sheet-like reinforcing fiber sheet material 2 in the width direction. The thermoplastic resin sheet material 3 is adhered, and the adhesive thermoplastic resin material 4 that is melted or softened at a temperature lower than the melting temperature of the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material 2 of the thermoplastic resin sheet material 3. It is configured to adhere to the surface of the surface that is not. Note that the adhesive thermoplastic resin material 4 may adhere to the surface of the reinforcing fiber sheet material 2 on which the thermoplastic resin sheet material 3 is not attached. The thermoplastic resin reinforced sheet material 1 in FIG. 2 has a configuration in which the other sheet material is attached to both surfaces of one of the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3. In Fig.2 (a), it is the structure which the reinforcement fiber sheet material 2 adhered to both surfaces of the thermoplastic resin sheet material 3, and the surface which the thermoplastic resin sheet material of one or both reinforcement fiber sheet materials does not adhere to. A thermoplastic resin material for adhesion is adhered to the surface of the substrate. In FIG.2 (b), it becomes the structure which the thermoplastic resin sheet material 3 adhered to both surfaces of the reinforcement fiber sheet material 2, and the surface which the reinforcement fiber sheet material of one or both thermoplastic resin sheet materials does not adhere to. A thermoplastic resin material for adhesion is adhered to the surface of the substrate.

Since the thermoplastic resin material 4 for adhesion adheres to the surface, when the thermoplastic resin reinforcing sheet material is cut and laminated in a required direction, the thermoplastic resin material for adhesion melts. Alternatively, by heating or heating and pressing at a softening temperature, the layers of the laminated thermoplastic resin reinforcing sheet material can be bonded and integrated with the adhesive thermoplastic resin material. In other words, it becomes easier to handle the laminated thermoplastic resin reinforcing sheet material, and when installing in a mold for molding, the reinforcing fiber is laminated while maintaining the reinforcing fiber reinforcement direction and the reinforcing fiber alignment state. In addition, the thermoplastic resin reinforced sheet material can be easily installed in the mold.

The reinforcing fiber sheet material constituting the thermoplastic resin reinforcing sheet material is often formed using a reinforcing fiber bundle in which a plurality of reinforcing fibers are bundled so as not to be separated by a sizing agent or the like. In this case, since the base material (matrix) resin is a thermoplastic resin, it is desirable to use a sizing agent in consideration of adhesiveness to the base material resin and the like as the sizing agent for bundling the reinforcing fiber bundle. And, by the effect that the sizing agent or the like adheres, it is possible to move each reinforcing fiber, shift each reinforcing fiber, etc. A reinforcing fiber sheet material excellent in drapeability can be obtained.

Considering the adhesion between the reinforcing fiber and the base resin, when using a reinforcing fiber bundle that does not adhere to the sizing agent or has a very small amount attached, or remove the sizing agent that adheres to the reinforcing fiber bundle. In some cases, a reinforcing fiber sheet material is used. Even in this case, it is possible to prevent the reinforcing fibers from being scattered by attaching the reinforcing fiber sheet material and the thermoplastic resin sheet material. In particular, if the number of reinforcing fibers arranged in the thickness direction is reduced by opening the reinforcing fiber bundle or the like, it is possible to further suppress the dispersion of the reinforcing fibers.

The adhesion of the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 in FIGS. 1 and 2 is a form in which the thermoplastic resin sheet material is thermally fused to one surface or both surfaces of the reinforcing fiber sheet material or a plurality of portions thereof, Alternatively, there is a form in which a reinforcing fiber sheet material and a thermoplastic resin sheet material are bonded to each other by thinly applying an adhesive that does not affect the mechanical properties when the molded product is formed. In addition, when the thermoplastic resin sheet material is heat-sealed to the reinforcing fiber sheet material, the thermoplastic resin sheet material may be slightly impregnated in the surface layer portion of the reinforcing fiber sheet material. It can be said that it has sufficient properties and is in the form of adhesion.

In addition, the thermoplastic resin sheet material shown in FIG. 2 has a configuration in which the other sheet material is attached to both surfaces of either the thermoplastic resin sheet material or the reinforcing fiber sheet material. The sheet material of the same material adheres so that the thermoplastic reinforcing sheet material does not curl on any one side. When the thermoplastic resin reinforced sheet material is thinned, deformation such as curling is likely to occur, but the planar shape of the sheet material can be maintained by the configuration shown in FIG.

Then, as shown in FIG. 2 (a), in the case of a thermoplastic resin reinforced sheet material in which the reinforcing fiber sheet material adheres to both surfaces of the thermoplastic resin sheet material, the blending ratio of both sheet materials is set to a predetermined value. When doing so, the thickness of the reinforcing fiber sheet material can be set thin by attaching the reinforcing fiber sheet material to each side of the thermoplastic resin sheet material in half. Therefore, when the thermoplastic fiber is impregnated in the reinforcing fiber sheet material, the impregnation distance is shortened.

When thinning the thermoplastic resin reinforced sheet material, it is necessary to reduce the thickness of the thermoplastic resin sheet material and the reinforced fiber sheet material, but the thickness of the reinforced fiber sheet material compared to the thermoplastic resin sheet material Since it is easy to reduce the thickness of the thermoplastic resin sheet material, a thin reinforcing fiber sheet material is attached to both surfaces of the thermoplastic resin sheet material, thereby making the thermoplastic resin reinforcing sheet material thinner and shortening the impregnation distance. be able to. Therefore, it is possible to obtain a molded product of good quality in which the voids such as voids are further reduced in a shorter time.

FIG. 3 is a schematic view showing a part of another thermoplastic resin reinforced sheet material 1 according to the embodiment of the present invention. The thermoplastic resin reinforcing sheet material 1 includes a thermoplastic resin sheet on one side of a reinforcing fiber sheet material 2 in which a plurality of reinforcing fiber bundles 2t, in which a plurality of reinforcing fibers 2f are bundled with a sizing agent, are aligned in the width direction. The material 3 is made to adhere by the adhesive thermoplastic resin material 4 which melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material. The thermoplastic resin sheet material 3 may be attached to both surfaces of the reinforcing fiber sheet material 2. Further, the reinforcing fiber sheet material 2 may be attached to both surfaces of the thermoplastic resin sheet material 3.

In FIG. 3, the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 are bonded together by an adhesive thermoplastic resin material 4 and integrated so as not to be separated, whereby the reinforcing fiber sheet material 2 and the thermoplastic resin sheet are integrated. The material 3 is adhered. That is, since the reinforcing fiber sheet material and the thermoplastic resin sheet material are adhered without being heated to the melting temperature of the thermoplastic resin sheet material, the form of the reinforcing fiber sheet material and the form of the thermoplastic resin sheet material are maintained. Yes. Therefore, the drapeability of the thermoplastic resin reinforced sheet material, the straight state of the reinforcing fiber, the uniform dispersed state, and the like are excellent sheet materials.

The thermoplastic resin reinforced sheet material 1 in FIG. 4 has a narrow thermoplastic resin sheet material 3 on one side of a narrow reinforcing fiber sheet material 2 in which a plurality of reinforcing fibers 2f are aligned. The narrow thermoplastic resin reinforced sheet material 1H is formed by using the narrow thermoplastic resin reinforced sheet material 1H that is adhered and configured by the adhesive thermoplastic resin material 4 that melts or softens at a temperature lower than the melting temperature of the material. Are arranged in the form of a plurality of sheets in the width direction. Thus, the thermoplastic resin reinforced sheet material 1 reinforced in one direction is obtained by arranging a plurality of the narrow thermoplastic resin auxiliary sheet materials 1H in the width direction and the thickness direction. Further, by weaving using the narrow thermoplastic resin reinforcing sheet material 1H as a woven yarn, for example, it is possible to obtain a thermoplastic resin reinforcing sheet material in which two directions of 0 degrees and 90 degrees are reinforced in advance.

Also in the narrow thermoplastic resin reinforcing sheet material 1H in FIG. 4, the narrow thermoplastic resin sheet material 3 is adhered to one surface of the narrow reinforcing fiber sheet material 2 by the adhesive thermoplastic resin material 4. However, a narrow thermoplastic resin sheet material may be adhered to both surfaces of the narrow reinforcing fiber sheet material by an adhesive thermoplastic resin material. Further, a narrow reinforcing fiber sheet material may be attached to both surfaces of a narrow-shaped thermoplastic resin sheet material by an adhesive thermoplastic resin material.

3 and 4, the adhesive thermoplastic resin material is not attached to the surface of the thermoplastic resin reinforced sheet material 1, but one or both surfaces of the thermoplastic resin reinforced sheet material 1 are illustrated. A thermoplastic resin material for adhesion may be distributed and adhered to the surface.

The thermoplastic resin reinforced sheet material is adhered to one or both sides of the adhesion amount per unit area of the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material. Different adhesion amounts per unit area of the adhesive thermoplastic resin material, and the adhesive thermoplastic resin material and the thermoplastic resin reinforcing sheet material for adhering the reinforcing fiber sheet material and the thermoplastic resin sheet material. The thermoplastic resin material for adhesion adhered to one side or both sides can be made different.

The adhesion amount per unit area of the adhesive thermoplastic resin material for adhering the reinforcing fiber sheet material and the thermoplastic resin sheet material to the adhesive thermoplastic resin material attached to one or both surfaces of the thermoplastic resin reinforcing sheet material More than the amount of adhesion per unit area, or the adhesive force of the adhesive thermoplastic resin material that bonds the reinforcing fiber sheet material and the thermoplastic resin sheet material is adhered to one or both surfaces of the thermoplastic resin reinforced sheet material. By selecting a material larger than the adhesive strength of the adhesive thermoplastic resin material, the adhesive strength between the reinforcing fiber sheet material and the thermoplastic resin sheet material is made larger than the adhesive strength between the thermoplastic resin reinforced sheet materials. A thermoplastic resin multilayer reinforcing sheet material can be obtained.

Thereby, the shift | offset | difference between each lamination | stacking of a thermoplastic resin reinforcement sheet material is realizable, making the reinforcement fiber sheet material adhere to the thermoplastic resin sheet material. In other words, a thermoplastic multi-layer reinforcing sheet material that is easy to handle with a plurality of thermoplastic resin reinforcing sheet materials bonded and integrated, but the thermoplastic multi-layer reinforcing sheet material is placed in a mold for molding. In this case, the adhesion between the layers of the thermoplastic resin reinforcing sheet material is locally removed without damaging the alignment state or dispersion state of the reinforcing fibers in the curved surface shape portion in the mold, and the thermoplastic resin reinforcing sheet. The thermoplastic resin multilayer reinforcing sheet material can be adapted to the mold shape while shifting the respective layers of the material, and has a further excellent draping property. That is, it is possible to obtain a laminated molded product having a complicated shape with high quality.

Here, the adhesion force means that the reinforcing fiber sheet material and the thermoplastic resin sheet material, or the reinforcing fiber sheet material and the reinforcing fiber sheet material, or the thermoplastic resin sheet material and the thermoplastic resin sheet are used. It represents the force with which the material adheres, and a large adhesion means that the force to adhere is strong. Note that the reinforcing fiber sheet material and the thermoplastic resin sheet material adhere to each other when the reinforcing fiber sheet material and the thermoplastic resin sheet material are used in normal handling, for example, handling the sheet material, lifting, cutting the sheet material, etc. Refers to a state in which peeling does not occur.

The thickness or weight of the thermoplastic resin sheet material 3 attached to the reinforcing fiber sheet material 2 is related to the basis weight of the reinforcing fiber sheet material (fiber weight per unit area) and the fiber volume content when the molded product is formed. Can be decided.

The reinforcing fiber sheet material 2 is formed by, for example, arranging a plurality of reinforcing fiber bundles 2t that are bundled so that the plurality of reinforcing fibers 2f are not separated by a sizing agent or the like into a sheet shape. The reinforcing fibers 2f include high-strength and high-modulus inorganic fibers and organic materials used for FRP such as carbon fibers, glass fibers, ceramic fibers, aramid fibers, PBO (polyparaphenylene benzobisoxazole) fibers, and metal fibers. Examples thereof include fibers. A plurality of fiber bundles in which these fibers are bundled may be combined. The fineness is not particularly limited.

By making the thickness of the reinforcing fiber sheet material 2 within 10 times the diameter of the reinforcing fiber 2f, the distance that the thermoplastic resin sheet material flows between the reinforcing fibers for impregnation becomes shorter when forming a molded product. A carbon fiber representative as a reinforcing fiber of the composite material has a single yarn diameter of 0.005 to 0.007 mm. Therefore, the thickness of the reinforcing fiber sheet material 3 is 0.05 to 0.07 mm or less. With reference to the model calculation in Non-Patent Document 1, it is expected that the thermoplastic resin sheet material will be impregnated in the reinforcing fiber bundle in about several seconds, and a molding process can be realized in a short time. In addition, by shortening the distance that flows between the reinforcing fibers of the thermoplastic resin sheet material, the disturbance of orientation of the reinforcing fibers due to the resin flow is suppressed, the uniform dispersibility of the reinforcing fibers is improved, and there are few voids Can be obtained.

In order to make the thickness of the reinforcing fiber sheet material 2 within 10 times the diameter of the reinforcing fiber 2f, there are a method using a fiber bundle with a small number of bundles, a method of opening the fiber bundle, and the like. The method by opening can make a fiber bundle having a large number of bundles (thick fiber bundle) into a thin and wide state. The thick fine fiber bundle has a relatively low material cost, so that a low-cost molded product can be obtained. In addition, the form of the spread yarn is stabilized by the effect of the sizing agent used in the state of the raw yarn.

The thermoplastic resin sheet material 3 serves as a base material (matrix) resin. Polypropylene, polyethylene, polystyrene, polyamide (nylon 6, nylon 66, nylon 12, etc.), polyacetal, polycarbonate, acrylonitrile-butadiene-styrene copolymer ( ABS), polyethylene terephthalate, polybutylene terephthalate, polyetherimide, polyethersulfone, polyphenylene sulfide, polyetherketone, polyetheretherketone and the like are used. Further, two or more of these thermoplastic resins may be mixed to form a polymer alloy and used as a base material (matrix) resin.

The thermoplastic resin material 4 for bonding is a material in which the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 are bonded and integrated, and is melted or softened at a temperature lower than the melting temperature of the configured thermoplastic resin sheet material. The reinforcing fiber sheet material and the thermoplastic resin sheet material, and the reinforcing fiber sheet material or the thermoplastic resin sheet material and the thermoplastic resin capable of bonding the release sheet material are used. The adhesive thermoplastic resin material 4 adheres to one or both surfaces of at least one of the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3. Preferably, it is desirable that the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 adhere to the surface of one or both surfaces of the thermoplastic resin sheet material 3 and are evenly dispersed. Thereby, the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 are securely bonded, and the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material, or a plurality of thermoplastic resin reinforcing sheet materials are laminated. To make the united and integrated.

The adhesive thermoplastic resin material 4 may be in either a powder shape or a fiber shape. Furthermore, in the case of a fiber shape, forms such as a state in which long fibers or short fibers are scattered and a fabric state such as a woven fabric, a knitted fabric, and a non-woven fabric can be used.

Furthermore, as the thermoplastic resin material 4 for bonding, a resin having a melting point in the range of 80 to 250 degrees is preferable. For example, polyamide, copolymer polyamide, polyurethane, or the like is selected. In particular, the copolymerized polyamide has a low melting point and good adhesiveness with a thermoplastic resin sheet material as a base material, and is preferable as an adhesive thermoplastic resin material. Furthermore, it is desirable to select a thermoplastic resin material for bonding that is compatible with the thermoplastic resin sheet material to be formed. Thereby, when the adhesive thermoplastic resin material is melted in the thermoplastic resin material serving as the base material, the adhesive thermoplastic resin material can be well present in the thermoplastic resin material serving as the base material.

The adhesion amount per unit area of the adhesive thermoplastic resin material 4 is preferably within 3% of the weight per unit area of the reinforcing fiber sheet material, and more preferably within the range of 0.5 to 2%. More preferred. By reducing the amount of the adhesive thermoplastic resin material 4 used, it is possible to reduce the influence on the mechanical properties and thermal properties of the composite material molded product from which the adhesive thermoplastic resin material is obtained.

Desirably, the adhesive thermoplastic resin material 4 is distributed on the surface of one or both surfaces of at least one of the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3, and is further uniformly distributed on the surface. It is more desirable. Thereby, even if the thermoplastic resin material for adhesion is 3% or less, more preferably in the range of 0.5 to 2%, the reinforcing fiber sheet material and the thermoplastic resin sheet material can be reliably adhered, that is, adhered. By attaching the reinforcing fiber sheet material to the thermoplastic resin sheet material, it is possible to maintain the form of each fiber bundle constituting the reinforcing fiber sheet material, that is, the state in which the reinforcing fibers are straightly arranged or uniformly dispersed In addition, the form of the thermoplastic resin sheet material maintains the form as a sheet, and the sheet material is excellent in handling.

Although not shown in FIGS. 1 to 4, the release sheet material can be bonded and integrated with the thermoplastic resin reinforcing sheet material by the bonding thermoplastic resin material 4. In particular, the form of the reinforcing fiber sheet material is maintained by adhering the release sheet material to the reinforcing fiber sheet material side of the thermoplastic resin reinforcing sheet material, and each reinforcing fiber constituting the reinforcing fiber sheet material is straight. It is possible to maintain a more stable state, a uniformly dispersed state, and the like.

In addition, as a release sheet material, a polyolefin resin sheet, a thermosetting polyimide resin sheet, a release film such as a fluororesin sheet, or a release paper can be selected.

FIG. 5 is a schematic view showing a part of the thermoplastic resin multilayer reinforcing sheet material 5 according to the embodiment of the present invention. The thermoplastic resin multilayer reinforcing sheet material 5 is formed by laminating the four thermoplastic resin reinforcing sheet materials 1A, 1B, 1C and 1D shown in FIGS. 1 to 3 and bonding and integrating them with the adhesive thermoplastic resin material. It is configured. In FIG. 5, thermoplastic resin reinforcing sheet materials 1A, 1B, 1C and 1D are laminated so that the reinforcing fibers of the respective thermoplastic resin reinforcing sheet materials are arranged in different axial directions.

FIG. 6 is a schematic view showing a part of another thermoplastic resin multilayer reinforcing sheet material 5 according to the embodiment of the present invention. The thermoplastic resin multilayer reinforcing sheet material 5 is made of the same material as the thermoplastic resin sheet material in a state in which the four thermoplastic resin reinforcing sheet materials 1A, 1B, 1C and 1D shown in FIGS. They are integrated by a thermoplastic resin fiber bundle 6 for integration. In FIG. 6, the thermoplastic resin reinforcing sheet materials 1A, 1B, 1C and 1D are laminated so that the reinforcing fibers of the thermoplastic resin reinforcing sheet materials are arranged in different axial directions. And each thermoplastic resin reinforcement sheet | seat material is integrated using the thermoplastic resin fiber bundle 6 for integration.

The thermoplastic resin fiber bundle 6 for integration uses thermoplastic resin fibers made of the same material as the used matrix resin. The same material may have the same main chemical composition, and the molecular weight, crystallinity, type of compound, and the like may be different. Since the resin is heated and melted when a molded product is obtained, if the chemical composition of the main polymer is the same, the thermoplastic resin sheet material and the thermoplastic resin fiber bundle for integration are melt-mixed, and the base material (matrix) and It becomes.

Further, when the thermoplastic resin sheet material is a polymer alloy, it is desirable to use a thermoplastic resin fiber bundle for integration with the polymer alloy resin. Alternatively, a thermoplastic resin fiber bundle for integration using one kind of thermoplastic resin may be used. Although the mixing ratio of the thermoplastic resin constituting the polymer alloy slightly changes locally by heating and melting to obtain a molded product, the thermoplastic resin sheet material used as a base material (matrix) and the thermoplastic resin for integration Since the fiber bundle is melt-mixed and the shape of the fiber disappears, it is possible to obtain a molded product in which the uniform dispersibility and the surface smoothness of the reinforcing fiber are improved without any deterioration in the mechanical properties.

The thermoplastic resin multilayer reinforcing sheet material 5 of FIGS. 5 and 6 is formed by laminating four sheets of thermoplastic resin reinforcing sheet materials 1A, 1B, 1C and 1D, but the number of laminated sheets is limited to four. What is necessary is just a lamination | stacking number of sheets of 2 or more. At this time, the thermoplastic resin reinforcing sheet material may be laminated in the same direction or in different directions. 5 and 6, the thermoplastic resin reinforced sheet material 1A is in the 0 degree direction, the thermoplastic resin reinforced sheet material 1B is in the 45 degree direction, the thermoplastic resin reinforced sheet material 1C is in the 90 degree direction, and the thermoplastic resin reinforced sheet material. 1D is fiber reinforced in the -45 degree direction.

Drawing 7 is an explanatory view about the manufacturing process of a thermoplastic resin reinforcement sheet material. After the thermoplastic fiber sheet material 3 is bonded and heat-sealed to one side of the reinforcing fiber sheet material 2 in which the reinforcing fiber spread yarn S obtained by opening the reinforcing fiber bundle 2t is aligned in the width direction, the thermoplastic resin sheet It is explanatory drawing regarding the process of spraying the powdery thermoplastic resin material 4 for adhesion on the surface of the material 3, and making it adhere by heat fusion | fusion, and manufacturing the thermoplastic resin reinforcement sheet material 1. FIG. 7A is a top view and FIG. 7B is a front view.

7 includes a multiple fiber bundle supply mechanism 601, a multiple fiber bundle opening mechanism 602, a longitudinal direction vibration applying mechanism 603, a width direction vibration applying mechanism 604, a heating mechanism 605, a cooling mechanism. A mechanism 606, a thermoplastic resin sheet material supply mechanism 607, a release sheet material supply mechanism 608, a release sheet material take-up mechanism 609, and a reinforcing sheet material take-up mechanism 610 are configured.

By the multiple fiber bundle supply mechanism 601, a plurality of reinforcing fiber bundle bobbins 2b around which the reinforcing fiber bundle 2t is wound can be installed, and each reinforcing fiber bundle 2t can be sent out with a substantially constant tension.

The supplied plurality of reinforcing fiber bundles 2t are widened and thinned by a multiple fiber bundle opening mechanism 602. The present opening mechanism employs an air opening method in which a fluid flowing from one direction (suction air flow in FIG. 7) is applied to each fiber bundle using a wind tunnel tube, that is, a known technique described in Patent Document 7 is adopted. doing. Any fiber opening method may be adopted as long as each reinforcing fiber bundle 2t is opened.

Inside the wind tunnel, two or more fixed or rotating rolls are installed at a certain interval, and each reinforcing fiber bundle 2t is in contact with the upper, lower, upper, lower,..., Upper part of the installed roll. Then run. Each reinforcing fiber bundle 2t is alternately given a tension state, a relaxation state, a tension state, a relaxation state, and so on by the longitudinal vibration applying mechanism 603. Therefore, when the reinforcement fiber bundle 2t is in a relaxation state in the wind tunnel, The reinforcing fiber bundle 2t running under the roll is bent instantaneously in the direction in which air flows, and each fiber moves in the width direction to perform fiber opening. When the reinforcing fiber bundle 2t is in a tension state, the fiber is straightened while maintaining the spread width because the fiber bundle is pressed against the upper and lower portions of the roll in the opened state. The reinforcing fiber bundle 2t travels while repeating this state, and enters the state of the reinforcing fiber spread yarn S immediately after the wind tunnel.

By adopting this method, the reinforcing fiber bundle 2t can be processed into a wide and thin reinforcing fiber spread yarn S in which the reinforcing fibers 2f constituting it are dispersed with high productivity. In the case of a carbon fiber bundle in a non-twisted state, it can be opened at a processing speed of 5 m / min or more with good dispersibility of the reinforcing fibers to about 2 to 7 times the width in the original yarn state.

A plurality of reinforcing fiber spread yarns S arranged in the width direction are vibrated in the width direction by a width direction vibration applying mechanism 604, that is, a spread fiber sheet without gaps between the reinforcing fiber spread yarns S, that is, reinforcing fibers. Becomes a reinforcing fiber sheet material 2 which is dispersed and thin.

Thereafter, the reinforcing fiber sheet material 2 is bonded to the thermoplastic resin sheet material 3 on one side of the reinforcing fiber sheet material 2 and travels on the heating roll 9 of the heating mechanism 605, whereby heat is applied to one side of the reinforcing fiber sheet material 2. The plastic resin material 3 is attached by heat sealing. The release sheet material 7 is supplied from the release sheet material supply mechanism 608 between the reinforcing fiber sheet material 2 and the heating roll 9. Then, after passing through the reversing roll 11, on the next heating roll 9, the surface of the thermoplastic resin sheet material 3 adhering to the reinforcing fiber sheet material 2 is powdered by the powder spraying device 8 and is used for the adhesive thermoplastic resin material. 4 is sprayed, and the adhesive thermoplastic resin material 4 is attached to the thermoplastic resin sheet material 3 by heat fusion. And the thermoplastic resin sheet material 3 travels on the cooling roll 10 of the cooling mechanism 606, the thermoplastic resin sheet material 3 adheres to one side of the reinforcing fiber sheet material 2, and the adhesive thermoplastic resin material 4 adheres to the surface thereof. Material 1 is obtained. The obtained thermoplastic resin reinforcing sheet material 1 is wound around the thermoplastic resin reinforcing sheet material wound body 1b by the reinforcing sheet material winding mechanism 610. Further, the release sheet material 7 is wound around the release sheet material winding mechanism 609.

In this mechanism, a thermoplastic resin sheet material is bonded to the reinforcing fiber sheet material, and the thermoplastic resin sheet material is melted or softened by heating, and is thermally fused, that is, attached to the reinforcing fiber sheet material. Depending on the heating conditions and the like, the surface layer portion of the reinforcing fiber sheet material may be impregnated with the thermoplastic resin sheet material, but the amount thereof is small, and the drapeability of the thermoplastic resin reinforcing sheet material can be sufficiently obtained. Since the purpose is not to impregnate the reinforcing fiber sheet material with the thermoplastic resin sheet material, the processing speed can be set fast and it is not necessary to set a high pressurizing force. That is, the thermoplastic resin reinforced sheet material can be manufactured with high productivity.

In FIG. 7, the thermoplastic resin sheet material 3 is bonded to one side from the upper side of the reinforcing fiber sheet material 2, but the thermoplastic resin sheet material 2 may be bonded from the lower side and from both the upper and lower sides. It is also possible to paste them together. Furthermore, as shown in FIG. 8, another set of mechanisms 601 to 604 may be prepared on the opposite side of the heating mechanism 605, and the reinforcing fiber sheet material 2 may be bonded to both sides of the thermoplastic resin sheet material 3.

In FIG. 7, after the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material, the powdery adhesive thermoplastic resin material is sprayed on the next heating roll and thermally fused to the surface of the thermoplastic resin sheet material. However, the temperature of the heating roll can be set lower than the melting temperature of the thermoplastic resin sheet material. Further, since heat fusion is the purpose, only heating may be used. However, if necessary, heating and pressurization using a pressing roll or the like may be performed. Furthermore, although the adhesive thermoplastic resin material is sprayed only on one side of the thermoplastic resin sheet material, the adhesive thermoplastic resin material may be sprayed on one side of the reinforcing fiber sheet material.

As the thermoplastic resin sheet material 3, a sheet-shaped material such as a thermoplastic resin film or a thermoplastic resin nonwoven fabric can be used. Also, an extrusion mechanism is prepared, and the thermoplastic resin pellets or thermoplastic resin powder are kneaded and melted with an extruder, extruded in a film form using a T die or the like, and the film is directly reinforced fiber sheet material 2 Also good to paste. Further, a sheet material in which a thermoplastic resin fiber bundle in which a plurality of thermoplastic resin fibers are bundled is aligned in the width direction to form a sheet, or a sheet material in which the thermoplastic resin fiber bundle is opened to form a sheet, etc. It can also be used.

In particular, since the thermoplastic resin film has a smooth surface, adhesion of the thermoplastic resin material for adhesion to the thermoplastic resin film is easy to be performed uniformly on the entire surface of the sheet, and therefore a small amount of thermoplastic resin material for adhesion is required. Even if it exists, adhesion etc. of a reinforcing fiber sheet material and a thermoplastic resin film are performed favorably.

As the adhesion of the thermoplastic resin material 4 for adhesion, a fixed amount is uniformly dispersed on the surface of the reinforcing fiber sheet material or the thermoplastic resin sheet material by the powder dispersion device 8 using the powdery thermoplastic resin material for adhesion. And a non-woven adhesive thermoplastic resin material, and a method of attaching and adhering to the surface of the reinforcing fiber sheet material or the thermoplastic resin sheet material. Also, the adhesive thermoplastic resin material is dissolved in a solvent to form a solution, and the solution is applied to the surface of the reinforcing fiber sheet material or thermoplastic resin sheet material, and the solvent is volatilized to reinforce the reinforcing fiber sheet material or thermoplastic resin. A method of attaching an adhesive thermoplastic resin material to the surface of the resin sheet material can be used. Note that the adhesive thermoplastic resin material 4 is preferably uniformly attached to the sheet material. Further, the adhesion amount per unit area of the adhesive thermoplastic resin material is 3% of the weight per unit area of the reinforcing fiber sheet material. It should be within.

Drawing 9 is an explanatory view about another manufacturing process of a thermoplastic resin reinforcement sheet material. After obtaining the reinforcing fiber spread yarn S from the reinforcing fiber bundle 2t, the process up to the step of obtaining the reinforcing fiber sheet material 2 is the same as in FIG. Thereafter, a powdery thermoplastic resin material 4 for adhesion is sprayed on one side of the reinforcing fiber sheet material 2, and the thermoplastic resin sheet material 3 is bonded and heat-sealed to the surface, thereby the thermoplastic resin reinforcing sheet material. It is explanatory drawing regarding the process of manufacturing 1. FIG. 9A is a top view and FIG. 9B is a front view.

FIG.10 and FIG.11 is also explanatory drawing regarding another manufacturing process of a thermoplastic resin reinforcement sheet material. In FIG. 10, a thermoplastic resin reinforced sheet material 1 is manufactured by spraying an adhesive thermoplastic resin material 4 on the thermoplastic resin sheet material 3 and bonding the reinforcing fiber sheet material 2 to the surface of the thermoplastic resin sheet material 3. It is explanatory drawing regarding a process. FIG. 11 shows a thermoplastic resin material which is dispersed by spraying the adhesive thermoplastic resin material 4 on one surface of the thermoplastic resin sheet material 2 of the thermoplastic resin reinforced sheet material obtained in FIG. It is explanatory drawing regarding the process of manufacturing the reinforcement sheet material. 10 and 11 are front views.

In FIGS. 9, 10, and 11, the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3 are adhered by the adhesive thermoplastic resin material 4. At this time, the melting or softening temperature of the adhesive thermoplastic resin material 4 that expresses the function capable of bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material is lower than the melting temperature of the thermoplastic resin sheet material 3, The set temperature of the heating roll 9 can be set to a temperature lower than the melting temperature of the thermoplastic resin sheet material. Therefore, the shrinkage of the thermoplastic resin sheet material that may occur due to heating can be prevented or made very small, and a high-quality thermoplastic resin reinforced sheet material without fiber meandering can be obtained.

In FIG. 11, the adhesive thermoplastic resin material 4 adheres to both surfaces of the thermoplastic resin sheet material. In this case, the total adhesion amount per unit area of the thermoplastic resin material for adhesion adhering to both surfaces of the thermoplastic resin sheet material is preferably within 3% of the weight per unit area of the reinforcing fiber sheet material. That is, the total adhesion amount per unit area of the thermoplastic resin material for bonding used in the thermoplastic resin reinforcing sheet material is within 3%, preferably 0.5 to 2% of the weight per unit area of the reinforcing fiber sheet material. The adhesive thermoplastic resin material is used in such a range.

Further, in FIG. 11, the spraying amount or resin of the adhesive thermoplastic resin material 4 sprayed on the surface of the thermoplastic resin sheet material 3 in order to bond and heat-bond the reinforcing fiber sheet material 2 and the thermoplastic resin sheet material 3. You may use the quantity or kind different from the application quantity or resin kind of the thermoplastic resin material 4 for adhesion | attachment sprayed on the single side | surface of the thermoplastic resin reinforcement sheet material 1 in a subsequent process.

In FIGS. 7 to 11, a thermoplastic resin sheet material is adhered on the same line immediately after opening a plurality of reinforcing fiber bundles into a spread yarn sheet. Thereby, a thermoplastic resin sheet material can be made to adhere immediately after the dispersibility of a reinforcement fiber will be in a good state.

7 to 11, a plurality of cooling rolls 10 are provided as the cooling mechanism 606. The set temperature of the cooling roll 10 is lower than the set temperature of the heating roll 9, but air cooling or water cooling may be performed when rapid cooling is desired. Conversely, when it is desired to perform slow cooling, it is preferable to provide a temperature gradient to a plurality of cooling rolls and gradually cool them. Whether to perform rapid cooling or slow cooling may be determined by considering the form of the thermoplastic resin reinforced sheet material to be produced.

Further, in the apparatus shown in FIGS. 7 to 11 and the like, when the molten or softened adhesive thermoplastic resin material adheres to the cooling roll, the adhesive thermoplastic resin material is sprayed and then released to the other surface. It is also possible to carry out a method in which the sheet material for stacking is released and the thermoplastic resin reinforced sheet material is sandwiched between the sheet material for release, and the sheet material for release is wound up after being discharged from the cooling roll.

The adhesive thermoplastic resin material is melted or softened by heating and solidified by cooling.At this time, the adhesive thermoplastic resin material shrinks to cause meandering of reinforcing fibers, shrinkage of the thermoplastic resin sheet material, etc. The quality of the thermoplastic resin reinforced sheet material may be impaired. In such a case, after spraying the adhesive thermoplastic resin material on the thermoplastic resin sheet material, heating and cooling may be performed while applying pressure. For example, in the apparatus shown in FIGS. 7 to 11 and the like, when the thermoplastic resin reinforcing sheet material travels in contact with the heating roll and the cooling roll, tension is applied to the thermoplastic resin reinforcing sheet material and the release sheet material. Thus, the thermoplastic resin reinforcing sheet material is pressed against each roll, and the heating roll and the cooling roll can be run while receiving continuous pressurization. Furthermore, you may use the press roll etc. for pressurization.

In the apparatus of FIGS. 7 to 11, although not shown, the adhesive thermoplastic resin material 4 can be dispersed and adhered to the surface of the release sheet material 7. Thereby, the thermoplastic resin reinforced sheet material 1 and the release sheet material 7 can be bonded and integrated. Then, the thermoplastic resin reinforcing sheet material 1 integrated with the release sheet material 7 is wound up by the reinforcing sheet material winding mechanism 610. In this case, the release sheet material winding mechanism 609 is not necessary.

In the apparatus of FIGS. 9 to 11, the reinforcing sheet material 2 and the thermoplastic resin sheet material 3 are bonded to the bonding heat by heating or heating and pressing at a temperature lower than the temperature at which the thermoplastic resin sheet material 3 melts. The thermoplastic resin reinforced sheet material 1 is produced by being attached by the plastic resin material 4. Accordingly, the heating roll 9 can be a low-temperature heating roll, and a relatively low-cost roll can be introduced. In particular, a wide heating roll can be easily introduced.

Moreover, since the release sheet material 7 to be used has a low heating temperature, release paper or the like can be used. Although a thermosetting polyimide resin sheet, a fluororesin sheet, or the like can be used as the release sheet material 7, the cost as the release sheet material increases. Therefore, the ability to use release paper as the release sheet material 7 enables low-cost production. Further, release papers having various widths and lengths are prepared, and the wide and long thermoplastic resin reinforced sheet material 1 can be easily manufactured. That is, it becomes possible to produce a thermoplastic resin reinforced sheet material having a width of 2 m or more.

In particular, when a heat-resistant thermoplastic resin sheet material made of a heat-resistant thermoplastic resin such as PPS resin, PEI resin, or PEEK resin is used as the thermoplastic resin sheet material 3, the heat-resistant thermoplastic resin sheet material is heated to the reinforcing fiber sheet material. In the method of directly adhering by fusing, the heat-resistant thermoplastic resin sheet material is melted or softened at the moment when the reinforcing fiber sheet material and the thermoplastic resin sheet material adhere to thermally fuse the reinforcing fiber and the thermoplastic resin. It is necessary to heat the equipment, the sheet material for release, etc. to the high temperature specification. However, in the method of adhering the reinforcing fiber sheet material and the heat-resistant thermoplastic resin sheet material with the adhesive thermoplastic resin material, the heating temperature can be lowered, and equipment for low temperature specifications, release sheet material, etc. A thermoplastic resin-reinforced sheet material made of a heat-resistant thermoplastic resin that can be used and that further suppresses initial cost and running cost can be obtained.

FIG. 12 is an explanatory diagram relating to a manufacturing process of a thermoplastic resin multilayer reinforcing sheet material. FIG. 12 is an explanatory diagram relating to a process for producing a thermoplastic resin multilayer reinforcing sheet material by laminating four sheets in the order of different fiber reinforcement directions using a wide thermoplastic resin reinforcing sheet material and then applying heat and pressure.

The sheet-type thermoplastic resin multilayer reinforced sheet material manufacturing apparatus 1000 in FIG. 12 includes an α-degree direction sheet material supply mechanism 1001, a 90-degree direction sheet material supply mechanism 1002, a −α-degree direction sheet material supply mechanism 1003, and a 0-degree direction sheet material. A supply mechanism 1004, a heat-bonding integrated mechanism 1005, a release sheet material supply mechanism 1006, a release sheet material take-up mechanism 1007, and a multilayer reinforcing sheet material take-up mechanism 1008 are configured.

The sheet material supply mechanism in each direction in the mechanisms 1001 to 1004 is a mechanism that pulls out and supplies the thermoplastic resin reinforcing sheet material 1 from the thermoplastic resin reinforcing sheet material winding 1b. The mechanisms 1001 to 1003 draw the thermoplastic resin reinforced sheet material 1 in the set direction beyond the width of the thermoplastic resin multilayer reinforced sheet material 5 and then cut the thermoplastic resin reinforced sheet by a cutting mechanism (not shown). After separating from the material wound body 1b, the thermoplastic resin multilayer reinforcing sheet material 5 is attached to the traveling rails 12 at both ends where the thermoplastic resin multilayer reinforcing sheet material 5 is traveled. At this time, the thermoplastic resin reinforcing sheet material to be attached is attached so that the end portion on the traveling direction side of the thermoplastic resin reinforcing sheet material is in contact with the end portion on the opposite side of the traveling direction of the thermoplastic resin reinforcing sheet material that has been pasted and run. When attached, in each layer of the thermoplastic resin multilayer reinforcing sheet material, there can be formed a sheet that reinforces the set direction without gaps or overlapping. In addition, pins (not shown) or the like are embedded in the traveling rail 12 so that the attached thermoplastic resin reinforcing sheet material can be fixed. The mechanism 1004 installs one or a plurality of thermoplastic resin reinforcing sheet material rolls 1b (not shown) so that the width of the thermoplastic resin multilayer reinforcing sheet material 5 can be obtained, and is reinforced with thermoplastic resin. The sheet material 1 is continuously supplied in the 0 degree direction.

In FIG. 12, the sheet material supply mechanism in each direction in the mechanisms 1001 to 1004 is a mechanism that pulls out and supplies the thermoplastic resin reinforcing sheet material 1 from the thermoplastic resin reinforcing sheet material roll 1b. When the release sheet material adheres to the thermoplastic resin reinforced sheet material 1, the sheet material supply mechanism releases the thermoplastic resin reinforced sheet material 1 from the thermoplastic resin reinforced sheet material 1b drawn out. Adopt a mechanism to peel off the sheet material. Thereby, only the thermoplastic resin reinforcing sheet material 1 is supplied.

Mechanisms 1001 and 1003 are mechanisms for supplying the thermoplastic resin reinforcing sheet material in the directions of α degrees and −α degrees. At this time, α degree can be set in a range of 0 degree <α degree <90 degrees, but is preferably in a range of 30 to 60 degrees in view of the size of the apparatus, ease of handling, and the like. Further, the supply direction, the supply number, the supply sequence, and the like of the thermoplastic resin reinforcing sheet material can be freely set, but it is desirable to determine them in accordance with the design of the molded product. For example, when a pseudo-isotropic material is obtained, the thermoplastic resin reinforced sheet material is [45 degrees / 0 degrees / −45 degrees / 90 degrees] or [45 degrees / −45 degrees / 0 degrees / 90 degrees]. It is good to laminate.

After the thermoplastic resin reinforced sheet material is laminated in multiple layers, the heat-bonding-type integrated mechanism 1005 is caused to run by bringing the release sheet material 7 into contact with both the upper and lower surfaces, and is heated or heated by the heating roll 9 from above and below. Heating and pressurizing are performed to melt or soften the adhesive thermoplastic resin material of each layer to heat-seal the thermoplastic resin reinforcing sheet material in the upper and lower layers. Then, after the molten or softened adhesive thermoplastic resin material is solidified by the cooling roll 12 and the thermoplastic resin reinforcing sheet material of each layer is bonded and integrated, the release sheet materials on the upper and lower surfaces are separated, A thermoplastic resin multilayer reinforcing sheet material 5 is obtained. In FIG. 12, the heating rolls 9 are doubled so that heating or heating / pressing can be performed at a higher speed. In addition, what is necessary is just to determine the number of the heating roll 9 and the cooling roll 10 according to heating temperature and a processing speed.

Each layer is laminated and heated or heated and pressed so that the adhesive thermoplastic resin material exists between the layers so that the thermoplastic resin reinforcing sheet material of each layer is heat-sealed by the adhesive thermoplastic resin material. Do.

Further, at least one of the release sheet materials on both the upper and lower surfaces may be bonded and integrated with a thermoplastic resin multilayer reinforcing sheet material by an adhesive thermoplastic resin material. Thereby, a thermoplastic resin multilayer reinforcement sheet material can be further improved in shape, stabilized as a sheet, and handling can be improved.

The temperature at which the plurality of laminated thermoplastic resin reinforced sheet materials are heated is a temperature at which the adhesive thermoplastic resin material 4 is melted or softened. Therefore, the temperature is lower than the melting temperature of the thermoplastic resin sheet material 3. Therefore, it is possible to eliminate or reduce the shrinkage of the thermoplastic resin sheet material that may be caused by heating, and to obtain a high-quality thermoplastic resin multilayer reinforcing sheet material that does not cause fiber meandering or the like. It becomes. Further, since the thermoplastic resin sheet material 3 is not melt-impregnated into the reinforcing fiber sheet material, it is possible to obtain a thermoplastic resin multilayer reinforcing sheet material having excellent drape properties.

When a heating roll having a flat surface as shown in the figure is used as the heating roll 9, the entire sheet surface can be heated or heated and pressurized. In this case, a thermoplastic resin multilayer reinforcing sheet material bonded and integrated over the entire surface of the laminated thermoplastic resin reinforcing sheet material can be obtained. And, for example, when a heating roll having an uneven surface is used, it is possible to obtain a thermoplastic resin multilayer reinforcing sheet material that is partially bonded and integrated instead of the entire surface of a plurality of laminated thermoplastic resin reinforcing sheet materials. it can.

Multiple layers of thermoplastic resin reinforced sheet material are partially heated or heated and pressurized, and partially bonded and integrated, and the thermoplastic resin multilayer reinforced sheet material is slightly more than the thermoplastic resin reinforced sheet material between each layer. Therefore, the sheet material can be more excellent in drapeability.

In addition, although the method using a heating roll as shown in FIG. 12 was demonstrated as a method of heating or heat-pressing the thermoplastic resin reinforcement sheet material laminated | stacked in multiple sheets, other methods may be sufficient, for example, a heat press board And a method using a double press method using a metal belt.

FIG. 13 is an explanatory diagram relating to a mechanism in which the narrow thermoplastic resin-reinforced sheet material 1H is supplied while being aligned in the width direction in the sheet material supply mechanisms 1001 to 1003 of FIG.

While pulling out the thermoplastic resin reinforcing sheet material 1 from the thermoplastic resin reinforcing sheet material roll 1b around which the wide thermoplastic resin reinforcing sheet material 1 is wound, in the width direction of the thermoplastic resin reinforcing sheet material 1 With a plurality of cutter blades 13 and cutter blade receiving rolls 14 arranged at a required interval, the thermoplastic resin reinforced sheet material 1 is continuously cut in the sheet length direction at a required interval in the width direction, and a plurality of The narrow thermoplastic resin reinforced sheet material 1H is supplied while being manufactured. In addition, the width | variety of a narrow thermoplastic resin reinforcement sheet | seat material is determined according to the design of the thermoplastic resin multilayer reinforcement sheet | seat material obtained. In consideration of improving the drapeability as a sheet, the narrower the width, the better. However, if the width is too small, the narrow thermoplastic resin reinforced sheet material may be cut and lose continuity. Therefore, the width is preferably in the range of 1 mm to 20 mm, and more preferably in the range of 2 mm to 10 mm.

By employing this mechanism, it is possible to efficiently supply a plurality of narrow thermoplastic resin reinforcing sheet materials 1H in the width direction. The cutter blade 13 may be either rotated or fixed, but a round blade-shaped cutter blade 13 that freely rotates in accordance with the travel of the thermoplastic resin reinforced sheet material 1 and a receiving roll 14 provided below the cutter blade. And the method of running and cutting the thermoplastic resin reinforcing sheet material 1 in the meantime is one method that can cut the thermoplastic resin reinforcing sheet material 2 without the fluff of reinforcing fibers. In addition, as a method of cutting the wide-shaped thermoplastic resin reinforcing sheet material 1 at a predetermined interval in the width direction, a method of cutting with a laser or the like may be employed.

FIG. 14 shows a thermoplastic resin fiber bundle 6 for integration after forming four sheets of thermoplastic resin reinforcing sheet material 1H using the narrow thermoplastic resin reinforcing sheet material 1H in the order of different fiber reinforcement directions. It is explanatory drawing regarding the process of stitching by and manufacturing the thermoplastic resin multilayer reinforcement sheet material 5. FIG. The narrow sheet type thermoplastic resin multilayer reinforcing sheet material manufacturing apparatus 1200 of FIG. 14 includes an α degree direction narrow sheet material supply mechanism 1201, a 90 degree direction narrow sheet material supply mechanism 1202, and a −α degree direction narrow sheet material supply. A mechanism 1203, a 0-degree direction narrow sheet material supply mechanism 1204, a stitch type integration mechanism 1205, and a multilayer reinforcing sheet material winding mechanism 1206 are configured.

The narrow sheet material supply mechanism in each direction in the mechanisms 1201 to 1204 is a mechanism that pulls out the narrow thermoplastic resin reinforcing sheet material 1H from the plurality of narrow thermoplastic resin reinforcing sheet material bobbins 1Hb, and supplies them in a sheet form. It has become. The mechanisms 1201 to 1203 are arranged by aligning a plurality of narrow thermoplastic resin reinforcing sheet materials 1H into a sheet shape, and hooking on one end portion of the traveling rails 12 at both ends for traveling the thermoplastic resin multilayer reinforcing sheet material 5, Next, the operation of running toward the other end and hooking on the other end is repeated to form the thermoplastic resin reinforced sheet material in each layer. At this time, the narrow thermoplastic resin reinforcing sheet material 1H is continuous without being cut, and the plurality of narrow thermoplastic resin reinforcing sheet materials 1H are aligned in a state where there are few gaps and overlaps, and the setting direction It is formed as a sheet state for reinforcing the fiber. A pin (not shown) or the like is embedded in the traveling rail 12 so that a plurality of narrow thermoplastic resin reinforcing sheet materials can be hooked and fixed. The mechanism 1204 is configured such that a plurality of narrow thermoplastic resin reinforcing sheet materials are arranged in a sheet shape so that the width of the thermoplastic resin multilayer reinforcing sheet material 5 can be obtained, and the sheet-shaped narrow thermoplastic resin The reinforcing sheet material is continuously supplied in the 0 degree direction.

The bobbin 1Hb around which the narrow thermoplastic resin reinforcing sheet material 1H is wound is obtained by the method shown in FIG. 13, that is, the wide thermoplastic resin reinforcing sheet material 1 in the sheet length direction at a required interval in the width direction. After the continuous cutting, each narrow thermoplastic resin reinforcing sheet material may be wound around each bobbin or the like. Moreover, using a device as shown in FIG. 7 to FIG. 11, a narrow-width thermoplastic resin reinforcing sheet material is attached to one side of the narrow-width reinforcing fiber sheet material to form a narrow-width thermoplastic resin reinforcing sheet material. The narrow thermoplastic resin reinforcing sheet material 1 may be manufactured and wound on a bobbin or the like.

Mechanisms 1201 and 1203 are mechanisms for supplying the narrow thermoplastic resin reinforcing sheet material in the directions of α and −α degrees. Similarly to the case of the sheet-type thermoplastic resin multilayer reinforced sheet material manufacturing apparatus 1000 in FIG. 12, α degree can be set in the range of 0 degree <α degree <90 degrees, but the size of the apparatus, ease of handling, etc. , Preferably in the range of 30 to 60 degrees. In addition, the supply direction, the supply number, the supply sequence, and the like of the narrow thermoplastic resin reinforcing sheet material can be freely set, but it is desirable to determine them according to the design of the molded product.

Then, the thermoplastic resin fiber bundle 6 for integration is put into the stitch type integration mechanism 1205 in a state where the thermoplastic resin reinforcing sheet materials of each layer formed by the plurality of narrow thermoplastic resin reinforcing sheet materials 1H are laminated in multiple layers. Thus, the thermoplastic resin multilayer reinforcing sheet material 5 obtained by stitching and integrating each layer by stitching by a warp knitting method or the like is obtained. The stitch interval of the thermoplastic resin fiber bundle 6 for integration is preferably determined according to the design of the molded product. The obtained thermoplastic resin multilayer reinforcing sheet material 5 is wound around the thermoplastic resin multilayer reinforcing sheet material winding 5b by the multilayer reinforcing sheet material winding mechanism 1206.

At this time, stitching by the thermoplastic resin fiber bundle 6 for integration is performed at a certain interval in the width direction of the thermoplastic resin multilayer reinforcing sheet material 5. When the interval becomes small, the amount of the thermoplastic resin fiber bundle 6 for integration increases, and when the final molded product is obtained, the amount of the base material (matrix) increases and the fiber volume content decreases. On the contrary, when this space | interval becomes wide, the handling as a sheet | seat of the thermoplastic resin multilayer reinforcement sheet material 5 will become difficult, and the cutting and lamination | stacking of the thermoplastic resin multilayer reinforcement sheet material 5 will become difficult. The stitch interval of the thermoplastic resin fiber bundle 6 for integration may be determined according to the design of the molded product.

The obtained thermoplastic resin multilayer reinforcing sheet material 5 is cut at a required size and a required angle, laminated on a mold for molding, and then subjected to heat and pressure molding, so that the thermoplastic resin sheet material and the integral one are integrated. It is possible to produce a thermoplastic resin multilayer reinforced molded article in which the thermoplastic resin fiber bundles for impregnation are impregnated between the reinforcing fibers.

Further, as another method for producing a thermoplastic resin multilayer reinforcing sheet from the thermoplastic resin multilayer reinforcing sheet material, first, the obtained thermoplastic resin multilayer reinforcing sheet material 5 is made to have a required size and a required angle. After cutting and laminating on a mold for flat plate molding, heating and pressurizing are performed, so that a thermoplastic resin sheet material and a thermoplastic resin fiber bundle for integration are impregnated between reinforcing fibers in a flat plate-shaped preformed laminated material Manufacturing. Then, the preformed laminated material is heated by a heating method such as a far-infrared method until the thermoplastic resin as a base material (matrix) is softened or melted, and then the preformed laminated material in that state is used for molding. When set in a mold and press-molded with a press molding apparatus or the like, a thermoplastic resin multilayer reinforced molded product molded into a required shape is obtained.

The thermoplastic resin multilayer reinforcing sheet material has a reinforcing fiber sheet material and a thermoplastic resin sheet material in each layer, so that the thermoplastic fiber is well impregnated into the reinforcing fiber bundle and molding with less voids (voids) It becomes goods. In addition, since the impregnation distance of the thermoplastic resin is shortened, the reinforcing fiber is maintained in a straight state and a uniform dispersed state, and becomes a molded product excellent in surface smoothness.

[Reference Example 1] A thermoplastic resin reinforced sheet material was manufactured using the following materials. <Used material> (Fiber bundle used for reinforcing fiber bundle) manufactured by Mitsubishi Rayon Co., Ltd .; TR50S-15K, fiber diameter of about 7 μm, 15,000 fibers (resin used for thermoplastic resin sheet material) manufactured by Mitsubishi Plastics Co., Ltd .; Nylon 6 resin pellet (resin used for adhesive thermoplastic resin) manufactured by Toray Industries, Inc .; copolymer polyamide resin powder, CM842P48, low melting point (115 ° C.) resin <Manufacturing process> (1) Manufacturing as shown in FIG. In the apparatus, the reinforcing fiber bundles TR50S-15K are set at intervals of 13 mm and 24 mm, and each of the reinforcing fiber bundles is separated by a multi-fiber bundle opening mechanism and a longitudinal vibration applying mechanism that air-opens the multiple fibers at the same time. The reinforcing fiber spread yarn is opened to a 20 mm width reinforcing fiber, and then the reinforcing fiber spread yarn is vibrated in the width direction by the width direction vibration applying mechanism so that there is no gap between the reinforcing fiber spread yarns. To obtain a sheet material. The obtained reinforcing fiber sheet material had a width of 310 mm and a fiber basis weight (fiber weight per unit area) of about 42 g / m ² . (2) Instead of the thermoplastic resin sheet material supply mechanism shown in FIG. 7, an apparatus in which an extrusion apparatus and a T die are combined is installed, nylon 6 pellets are charged into the apparatus, and the width is 320 mm and the thickness is 15 μm. While producing 6 films, a nylon 6 resin film was adhered to one side of the reinforcing fiber sheet material by thermal fusion. No release sheet material was used. Moreover, the heating temperature of the heating roll 9 for bonding the reinforcing fiber sheet material and the nylon 6 resin film was controlled to 150 degrees. (3) Adhesive thermoplastic resin material using powder spraying device 8 on the nylon 6 resin film side surface of the sheet while running the sheet with the nylon 6 resin film adhered to one side of the reinforcing fiber sheet material The copolymerized polyamide resin powder was uniformly dispersed and adhered. The amount of dispersion was about 0.3 g / m ² and about 0.7% of the weight of the reinforcing fiber bundle was adhered. The heating temperature of the heating roll 9 was controlled at 120 degrees. The production rate of the reinforcing fiber sheet material, the production rate of the nylon 6 resin film by extrusion molding, and the rate of dispersing and adhering the copolymerized polyamide resin powder were about 8 m / min. <Evaluation> In the obtained thermoplastic resin reinforcing sheet material, first, the reinforcing fibers constituting the reinforcing fiber sheet material were uniformly dispersed in a straight state. Moreover, the nylon 6 resin film adhered to the entire surface of the reinforcing fiber sheet and stabilized the form of the reinforcing fiber spread yarn. There were no gaps or fiber bundling in the reinforcing fiber sheet material. In addition, copolymer nylon resin powder, which is a thermoplastic resin material for adhesion, was uniformly dispersed and adhered to one surface of the thermoplastic resin reinforced sheet material on the nylon 6 resin film side.

[Reference Example 2] A thermoplastic resin reinforced sheet material was produced using the following materials. <Materials Used> The reinforcing fiber bundle and the adhesive thermoplastic resin material are the same as those in Reference Example 1. (Resin used for thermoplastic resin sheet material) manufactured by Mitsubishi Plastics, Inc .; PEI (polyetherimide) resin film, film thickness 15 μm <Manufacturing process> (1) In a manufacturing apparatus as shown in FIG. By the method (1), a reinforcing fiber sheet material having a width of 310 mm and a fiber basis weight of about 42 g / m ² was obtained. (2) While running a PEI resin film, which is a thermoplastic resin sheet material, on one surface of the PEI resin film, a powder dispersion device 8 is used to uniformly disperse and adhere the copolymerized polyamide resin powder, which is a thermoplastic resin material for bonding. I let you. The amount of dispersion was about 0.3 g / m ² , which was about 0.7% of the weight of the reinforcing fiber bundle. (3) The PEI resin film in which the copolymerized polyamide resin powder was dispersed was bonded to the reinforcing fiber sheet material, and then was run on the heating roll and the cooling roll together with the release sheet material. As a result, the copolymerized polyamide resin powder was melted to obtain a thermoplastic resin reinforced sheet material in which the PEI resin film was adhered to the reinforced fiber sheet material. At this time, the temperature of the heating roll was controlled to about 120 degrees. Release paper was supplied to the release sheet material. The production speed of the reinforcing fiber sheet material, the speed at which the copolymerized polyamide resin powder is dispersed and attached to the PEI resin film, and the thermoplastic resin reinforcing sheet material are attached to the reinforcing fiber sheet material to produce the thermoplastic resin reinforcing sheet material. The speed was about 10 m / min. <Evaluation> In the obtained thermoplastic resin reinforcing sheet material, first, the reinforcing fibers constituting the reinforcing fiber sheet material were uniformly dispersed in a straight state. Moreover, the form of the reinforcing fiber spread yarn was stabilized by adhering to the PEI resin film, and no gaps or fiber convergence occurred in the reinforcing fiber sheet material. And the PEI resin film was hardly contracted by heating, and the sheet form was stabilized and adhered to the reinforcing sheet material.

[Reference Example 3] A thermoplastic resin reinforced sheet material was manufactured using the following materials. <Material used> The reinforcing fiber bundle is the same as in Reference Example 1. (Resin used for thermoplastic resin sheet material) manufactured by Toray Industries, Inc .; PPS (polyphenylene sulfide) resin film, film thickness 15 μm (resin used for adhesive thermoplastic resin material) manufactured by Toray Industries, Inc .; polyamide resin powder, SP- 500, melting point: 165 ° C. <Manufacturing process> (1) A reinforcing fiber sheet material having a width of 310 mm and a fiber basis weight of about 42 g / m ² was obtained by (1) of Reference Example 2. (2) While running the PPS resin film as the thermoplastic resin sheet material, the polyamide resin powder as the adhesive thermoplastic resin material was uniformly dispersed and adhered to one surface of the film using a powder spraying device. The amount of dispersion was about 0.5 g / m ² and about 0.12% of the weight of the reinforcing fiber bundle. (3) After a PPS resin film in which polyamide resin powder was dispersed was bonded to the reinforcing fiber sheet material, the sheet was moved to a heating roll and a cooling roll together with the release sheet material. Thereby, the polyamide resin powder was melted to obtain a thermoplastic resin reinforced sheet material in which the PPS resin film was adhered to the reinforced fiber sheet material. At this time, the temperature of the heating roll was controlled to about 200 degrees. Release paper was supplied to the release sheet material. The production speed of the reinforcing fiber sheet material, the speed at which the polyamide resin powder is dispersed and attached to the PPS resin film, and the speed at which the thermoplastic resin reinforcing sheet material is attached to the reinforcing fiber sheet material are It was performed at about 10 m / min. <Evaluation> In the obtained thermoplastic resin reinforced sheet material, as in Reference Example 2, each reinforcing fiber constituting the reinforced fiber sheet material was uniformly dispersed in a straight state. Moreover, the form of the reinforcing fiber spread yarn was stabilized by adhering to the PPS resin film, and no gaps or fiber convergence was generated in the reinforcing fiber sheet material. And the sheet | seat form of the PPS resin film was stable, and the thermoplastic resin reinforcement sheet material which is easy to handle was obtained.

Example 1 A thermoplastic resin reinforced sheet material was manufactured using the following materials. <Materials Used> Reinforcing fiber bundles and thermoplastic resin sheet materials are the same as in Reference Example 1. (Resin used for thermoplastic resin sheet material) manufactured by Mitsubishi Plastics, Inc .; nylon 6 resin film, film thickness 20 μm <Manufacturing process> (1) In the manufacturing apparatus as shown in FIG. Eight reinforcing fiber bundles TR50S-15K are set to each installed multiple fiber bundle supply mechanism 601 at an interval of 40 mm, and longitudinal vibration is applied to each reinforcing fiber bundle by each longitudinal vibration applying mechanism 603. Each of the multiple fiber bundle opening mechanisms 602 obtains a reinforcing fiber opening yarn in which each reinforcing fiber bundle is opened to a width of about 40 mm, and each width direction vibration applying mechanism 604 opens each reinforcing fiber opening. yarn and was vibrated in the width direction, there is no gap between the reinforcing fibers opened yarn, a width of about 320 mm, (fiber weight per unit area) fiber basis weight reinforcing fiber sheet of about 25 g / m ² It was obtained as a continuous, respectively. (2) After that, the respective reinforcing fiber sheet materials are continuously supplied to the heating roll 9 installed at the beginning of the heating mechanism 605, and at the same time, the thermoplastic resin sheet material is reinforced with the thermoplastic resin sheet material supplying mechanism 607. The reinforcing fiber sheet material was bonded to both surfaces of the thermoplastic resin sheet material with the heating roll 9 by inserting continuously between the sheet materials. At this time, the temperature of the heating roll 9 was controlled to about 270 degrees. A thermosetting polyimide resin film (product name: Upilex S, thickness: 25 μm, manufacturer: Ube Industries, Ltd.) was supplied as a release film together with the reinforcing fiber sheet material. (3) While running the sheet with the reinforcing fiber sheet material attached to both sides of the nylon 6 resin film, using the powder spreading device 8 on one side of the sheet material, that is, on the surface of the reinforcing fiber sheet material on one side The copolyamide resin powder, which is a thermoplastic resin material for adhesion, was uniformly dispersed and adhered. The dispersion amount was about 0.25 g / m ² , and an amount of about 0.5% of the reinforcing fiber bundle weight was adhered. The heating temperature of the heating roll 9 ′ in contact with the sheet material to which the adhesive thermoplastic resin material adhered was controlled to 120 degrees. In addition, the speed at which each reinforcing fiber bundle is opened and processed into a reinforcing fiber sheet material, the processing speed at which the reinforcing fiber sheet material is bonded to both surfaces of the thermoplastic resin sheet material, and the copolyamide resin powder are dispersed and adhered. The speed was about 10 m / min. (4) The thermoplastic resin as shown in FIG. 2A in which the reinforcing fiber sheet material is adhered to both surfaces of the thermoplastic resin sheet material by peeling the release film from the substrate discharged from the cooling mechanism 606. A reinforcing sheet material was obtained. <Evaluation> In the obtained thermoplastic resin reinforcing sheet material, first, the reinforcing fibers constituting the reinforcing fiber sheet material were uniformly dispersed in a straight state. Further, the reinforcing fiber sheet material adhered to the entire surface of both sides of the nylon 6 resin film, and the form of the reinforcing fiber spread yarn was stabilized. There were no gaps or fiber bundling in the reinforcing fiber sheet material. Further, the copolyamide resin powder as the adhesive thermoplastic resin material was uniformly dispersed and adhered to the surface of the reinforcing fiber sheet material of the thermoplastic resin reinforced sheet material. Further, the thermoplastic resin reinforced sheet material had no phenomenon such as curling of its end portion, and the flatness as a sheet was maintained.

[Reference Example 4] A thermoplastic resin multilayer reinforcing sheet material was produced from the thermoplastic resin reinforcing sheet material obtained by the method of Reference Example 2. <Used Material> Reinforcing fiber bundle, thermoplastic resin sheet material, and adhesive thermoplastic resin material are the same as in Reference Example 2. <Manufacturing Process> (1) A thermoplastic resin reinforced sheet material having a width of 310 mm was obtained by the method of (1) to (3) of Reference Example 2. The dispersion amount of the adhesive thermoplastic resin material was about 0.4 g / m ² and an amount of about 1% of the weight of the reinforcing fiber bundle was adhered. (2) Copolymer polyamide, which is a thermoplastic resin material for bonding, on the PEI resin film side surface of the obtained thermoplastic resin reinforced sheet material in a production apparatus as shown in FIG. Resin powder was uniformly dispersed and adhered. The amount of dispersion was about 0.2 g / m ² and about 0.5% of the reinforcing fiber bundle weight. (3) The obtained thermoplastic resin reinforced sheet material is laminated in a 45 degree direction, a 0 degree direction, a −45 degree direction, and a 90 degree direction in a manufacturing apparatus as shown in FIG. After making into a laminated sheet state, the copolymerized polyamide resin powder was melted by a heating mechanism, and the laminated thermoplastic resin reinforcing sheet material was bonded and integrated to obtain a thermoplastic resin multilayer reinforcing sheet material. At this time, the temperature of the heating roll was controlled to about 120 degrees. Release paper was supplied to the release sheet material. <Evaluation> The obtained thermoplastic resin multilayer reinforcing sheet material is a multiaxial reinforcing sheet material which is fiber-reinforced at [45 degrees / 0 degrees / −45 degrees / 90 degrees], and the reinforcing fibers are formed into sheets in each layer. It was formed, and the PEI resin film was attached to one side. The thermoplastic resin reinforced sheet material of each layer was uniformly dispersed with the reinforcing fibers being straight, and the PEI resin film was hardly contracted by heating, and the sheet form was stabilized. The thermoplastic resin reinforced sheet material of each layer was bonded and integrated with the copolymerized polyamide resin powder, and a thermoplastic resin multilayer reinforced sheet material excellent in drape and quality was obtained. The amount of copolymerized polyamide resin used for each thermoplastic resin reinforced sheet material was about 1.5% of the amount of carbon fiber used.

Reference Example 5 A plurality of narrow thermoplastic resin reinforcing sheet materials were obtained from the thermoplastic resin reinforcing sheet material obtained by the methods of Reference Examples 4 (1) and (2), and a thermoplastic resin multilayer reinforcing sheet material was obtained. Manufactured. <Used Material> Reinforcing fiber bundle, thermoplastic resin sheet material, and adhesive thermoplastic resin material are the same as in Reference Example 2. <Manufacturing process> (1) A thermoplastic resin reinforced sheet material having a width of 310 mm is obtained from Reference Examples 4 (1) and (2). (2) The obtained thermoplastic resin reinforced sheet material was continuously cut at a width of 10 mm with a manufacturing apparatus as shown in FIG. 13 to obtain 31 narrow width thermoplastic resin reinforced sheet materials. At this time, as the cutter blade and the cutting method, a round blade-like cutter blade that freely rotates according to the travel of the thermoplastic resin reinforcing sheet material is provided, and the thermoplastic resin reinforcing sheet material is pushed and cut between the cutter blade receiving roll. The method was adopted. And the obtained narrow thermoplastic resin reinforcement sheet material was wound up in tape shape. In addition, the speed | rate which cut | disconnects a wide-shaped thermoplastic resin reinforcement sheet | seat material was performed at 10 m / min. (3) In a manufacturing apparatus as shown in FIG. 12, 45 narrow-width thermoplastic resin reinforced sheet materials wound up in a tape shape are arranged in a wide sheet state so that no gap is generated in the width direction. After laminating in the direction of 0 degrees, 0 degrees, -45 degrees and 90 degrees to form a laminated sheet with a width of 310 mm, the copolymerized polyamide resin powder is melted by a heating mechanism, and the laminated thermoplasticity The resin reinforced sheet material was bonded and integrated to obtain a thermoplastic resin multilayer reinforced sheet material. At this time, the temperature of the heating roll was controlled to about 120 degrees. Release paper was supplied to the release sheet material. <Evaluation> The obtained thermoplastic resin multilayer reinforcing sheet material is a multiaxial reinforcing sheet material which is fiber-reinforced at [45 degrees / 0 degrees / −45 degrees / 90 degrees], and the reinforcing fibers are formed into sheets in each layer. It was formed, and the PEI resin film was attached to one side. The narrow thermoplastic resin reinforced sheet material of each layer was uniformly dispersed with the reinforcing fibers being straight, and the PEI resin film was hardly contracted by heating, and the sheet form was stabilized. Moreover, the fluff of the reinforcing fiber at the end portion of the cut thin thermoplastic resin reinforcing sheet material was very small and easy to handle. And since each layer was a narrow thermoplastic resin reinforcement sheet material, it became the thermoplastic resin multilayer reinforcement sheet material which was very excellent in drape property.

[Reference Example 6] Using the thermoplastic resin multilayer reinforcing sheet material prepared in Reference Example 4, a concave thermoplastic resin multilayer reinforcing molded product was produced. <Manufacturing process> (1) The thermoplastic resin multilayer reinforcing sheet material obtained in Reference Example 4 and the stacking order prepared by the same method as in Reference Example 4 [90 degrees / −45 degrees / 0 degrees / 45 degrees] After cutting 3 sheets of each of the thermoplastic resin multilayer reinforcing sheet material with a length of 310 mm in the longitudinal direction (0 degree direction), [45 degrees / 0 degrees / −45 degrees / 90 degrees], [45 degrees / 0 degrees / −45 degrees / 90 degrees], [45 degrees / 0 degrees / −45 degrees / 90 degrees], [90 degrees / −45 degrees / 0 degrees / 45 degrees], [ The layers were laminated in the order of 90 degrees / −45 degrees / 0 degrees / 45 degrees] and [90 degrees / −45 degrees / 0 degrees / 45 degrees]. Note that the molding die is a concave mold having a width of 250 mm, a length of 250 mm, and a depth of 20 mm, and a curved portion and a corner portion are rounded. (2) After setting the concave molding die in the hot press molding apparatus, lowering the convex molding die and applying pressure at 0.1 MPa, the molding takes 60 minutes. The mold temperature was raised to 380 degrees. (3) After the temperature rises, the convex mold is lowered, and heat and pressure molding is performed on the base material at a pressure of 1 MPa for 60 seconds. Slowly cooled. The cooling time was about 120 minutes. After cooling, the convex molding die was raised to obtain a thermoplastic resin multilayer reinforced molded product. <Evaluation> A concave thermoplastic resin multilayer reinforced molded product having a thickness of about 1 mm and a fiber volume content of about 60% was obtained. The surface of the molded product was excellent in smoothness. Moreover, the state of the reinforcing fiber on the surface was a state excellent in uniform dispersion while maintaining a straight state. As a result of cutting the molded product and observing the cross section, it was confirmed that a molded product having a straight state and a uniform dispersed state of the reinforcing fiber and having a small number of voids was obtained. Further, it was confirmed that the molded product was obtained in a good quality state without delamination even at the bent part and the corner part.

1, 1A, 1B, 1C, 1D Thermoplastic resin reinforcing sheet material 1b Thermoplastic resin reinforcing sheet material roll 1H Narrow thermoplastic resin reinforcing sheet material 1HB Narrow thermoplastic resin reinforcing sheet material bobbin 2 Reinforcing fiber sheet material 2f Reinforcement Fiber 2t Reinforcing fiber bundle 2b Reinforcing fiber bundle bobbin 3 Thermoplastic resin sheet material 4 Adhesive thermoplastic resin material 5 Thermoplastic resin multilayer reinforcing sheet material 5b Thermoplastic resin multilayer reinforcing sheet material roll 6 Integration thermoplastic resin fiber bundle 7 Sheet material for release 8 Powder dispersion device 9, 9 ′ Heating roll 10 Cooling roll 11 Reverse roll 12 Traveling rail 13 Cutter blade 13 Cutter blade receiving roll S Reinforcing fiber spread yarn 600 Thermoplastic resin reinforced sheet material manufacturing apparatus 01 Multiple fiber bundle supply mechanism 602 Multiple fiber bundle opening mechanism 603 Longitudinal vibration imparting mechanism 604 Width direction vibration imparting mechanism 605 Heating mechanism 606 Cooling mechanism 607 Thermoplastic resin sheet material supply mechanism 608 Release sheet material supply mechanism 609 Release sheet material winding mechanism 610 Reinforcing sheet material winding mechanism 1000 Sheet type thermoplastic resin multilayer reinforcing sheet material manufacturing apparatus 1001 α degree direction sheet material supply mechanism 1002 90 degree direction sheet material supply mechanism 1003 -α degree direction sheet material Supply mechanism 1004 0-degree direction sheet material supply mechanism 1005 Heat bonding type integrated mechanism 1006 Release sheet material supply mechanism 1007 Release sheet material take-up mechanism 1008 Multi-layer reinforcing sheet material take-up mechanism 1200 Narrow sheet type thermoplastic resin Many Reinforcing sheet material manufacturing apparatus 1201 α-degree direction fiber bundle supply mechanism 1202 90-degree direction fiber bundle supply mechanism 1203 —α-degree direction fiber bundle supply mechanism 1204 0-degree direction fiber bundle supply mechanism 1205 Stitch-type integration mechanism 1206 Multi-layer reinforcing sheet material winding Removing mechanism

Claims (23)

A reinforcing fiber sheet material in which a plurality of reinforcing fibers are aligned in a predetermined direction to form a sheet, a thermoplastic resin sheet material serving as a matrix resin attached to the reinforcing fiber sheet material, and the thermoplastic resin sheet material A thermoplastic resin material for adhesion that is melted or softened at a temperature lower than the melting temperature of the adhesive fiber and adhered to at least one of the reinforcing fiber sheet material and the thermoplastic resin sheet material. A thermoplastic resin reinforced sheet material, wherein the reinforcing fiber sheet material is attached to both surfaces of the resin sheet material so that the direction in which the reinforcing fibers are aligned is the same direction. 2. The reinforcing fiber sheet material and the thermoplastic resin sheet material are bonded by the adhesive thermoplastic resin material, and the thermoplastic resin sheet material is adhered to the reinforcing fiber sheet material. The thermoplastic resin reinforcing sheet material described in 1. The reinforcing fiber sheet material and the thermoplastic resin sheet material are thermoplastic resin reinforcing sheet materials bonded by the adhesive thermoplastic resin material, and the thermoplastic resin reinforcing sheet material is provided on one or both sides of the thermoplastic resin reinforcing sheet material. In the thermoplastic resin reinforced sheet material to which the adhesive thermoplastic resin material is adhered, the adhesion amount per unit area of the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material is, The thermoplastic resin reinforcing sheet material according to claim 2, wherein the thermoplastic resin reinforcing sheet material is different from an adhesion amount per unit area of the thermoplastic resin material for adhesion adhered to one or both surfaces of the thermoplastic resin reinforcing sheet material. The reinforcing fiber sheet material and the thermoplastic resin sheet material are thermoplastic resin reinforcing sheet materials bonded by the adhesive thermoplastic resin material, and the thermoplastic resin reinforcing sheet material is provided on one or both sides of the thermoplastic resin reinforcing sheet material. In the thermoplastic resin reinforcing sheet material to which the adhesive thermoplastic resin material is adhered, the adhesive thermoplastic resin material for bonding the reinforcing fiber sheet material and the thermoplastic resin sheet material is the thermoplastic resin reinforcing sheet material. The thermoplastic resin reinforced sheet material according to claim 2, wherein the thermoplastic resin material is different from the adhesive thermoplastic resin material attached to one or both sides of the thermoplastic resin material. The thermoplastic resin reinforced sheet material is attached to a release sheet material by the adhesive thermoplastic resin material, and the release sheet material is integrated with the thermoplastic resin reinforced sheet material. The thermoplastic resin reinforcing sheet material according to any one of 1 to 4. The thermoplastic resin according to any one of claims 1 to 5, wherein the reinforcing fiber sheet material has a cross-sectional thickness of the reinforcing fiber sheet material set within 10 times the diameter of the reinforcing fiber. Reinforcing sheet material. The thermoplastic resin according to any one of claims 1 to 6, wherein an adhesion amount per unit area of the adhesive thermoplastic resin material is within 3% of a weight per unit area of the reinforcing fiber sheet material. Reinforcing sheet material. A thermoplastic resin multilayer reinforcing sheet material, wherein a plurality of the thermoplastic resin reinforcing sheet materials according to any one of claims 1 to 7 are laminated and formed. The thermoplastic resin multilayer according to claim 8, wherein the thermoplastic fiber reinforced sheet material is laminated so that the reinforcing fiber sheet material obtained by aligning the reinforcing fibers in the same direction is multiaxial. Reinforcing sheet material. 10. The thermoplastic resin according to claim 8, wherein the thermoplastic resin material for bonding is heated and melted or heated and softened, and a plurality of laminated thermoplastic resin reinforcing sheet materials are bonded and integrated. Multi-layer reinforcing sheet material. The thermoplastic resin material for bonding is partially heated and melted or heated and softened, and a plurality of laminated thermoplastic resin reinforcing sheet materials are partially bonded and integrated. The thermoplastic resin multilayer reinforcing sheet material described in 1. 9. A plurality of laminated thermoplastic resin reinforcing sheet materials are stitched together by stitching and integrated with a thermoplastic resin fiber bundle for integration, which is the same material as the thermoplastic resin sheet material. Or the thermoplastic resin multilayer reinforcing sheet material according to 9; A sheet forming step of creating a sheet-like reinforcing fiber sheet material by aligning a plurality of reinforcing fibers in a predetermined direction, and the reinforcing fibers are aligned on both sides of a thermoplastic resin sheet material serving as a matrix resin. A temperature lower than the melting temperature of the thermoplastic resin sheet material on one side or both sides of the sheet material to which the reinforcing fiber sheet material and the thermoplastic resin sheet material are adhered after being adhered so that the directions are the same direction A method for producing a thermoplastic resin-reinforced sheet material, comprising: an adhesion step of adhering an adhesive thermoplastic resin material that is melted or softened at a time. A sheet forming step of creating a sheet-like reinforcing fiber sheet material by aligning a plurality of reinforcing fibers in a predetermined direction, and one or both surfaces of at least one of the reinforcing fiber sheet material and the thermoplastic resin sheet material serving as a matrix resin An adhesion step of adhering an adhesive thermoplastic resin material that melts or softens at a temperature lower than the melting temperature of the thermoplastic resin sheet material, and the reinforcing fiber sheet material on both sides of the thermoplastic resin sheet material. They are superposed so that the aligned directions are the same and the adhesive thermoplastic resin material is present between the two sheet materials, and heating or heating is performed at a temperature lower than the temperature at which the thermoplastic resin sheet material melts. Pressure bonding and melting or softening the adhesive thermoplastic resin material to adhere the reinforcing fiber sheet material and the thermoplastic resin sheet material When manufacturing a thermoplastic resin reinforcing sheet material, which comprises a. In the sheet forming step, the reinforcing fiber sheet material is formed into a sheet shape in which a plurality of reinforcing fibers are aligned in a predetermined direction and a cross-sectional thickness thereof is within 10 times the diameter of the reinforcing fibers. The manufacturing method of the thermoplastic resin reinforcement sheet material of Claim 13 or 14. In the sheet forming step, as the reinforcing fiber sheet material, a reinforcing fiber bundle in which a plurality of long-fiber reinforcing fibers are gathered is continuously widened in the width direction, and formed using wide open fibers. The method for producing a thermoplastic resin reinforced sheet material according to any one of claims 13 to 15, wherein: Overlaid so that the adhesive thermoplastic resin material exists between the reinforcing fiber sheet material and the release sheet material, and heated or heated and pressed at a temperature lower than the temperature at which the thermoplastic resin sheet material melts, The thermoplastic resin reinforced sheet material according to any one of claims 13 to 16, wherein the reinforcing fiber sheet material and the release sheet material are adhered by melting or softening the thermoplastic resin material for bonding. Manufacturing method. A release sheet material is superposed on the thermoplastic resin reinforced sheet material so that the adhesive thermoplastic resin material exists between the two sheet materials, and at a temperature lower than the temperature at which the thermoplastic resin sheet material melts. The heating or pressurizing is performed to melt or soften the adhesive thermoplastic resin material to adhere the thermoplastic resin reinforcing sheet material and the release sheet material. The manufacturing method of the thermoplastic resin reinforcement sheet material of description. A lamination step of superimposing at least one thermoplastic resin reinforcing sheet material according to any one of claims 1 to 7 in a thickness direction, and an integration for integrating a plurality of the thermoplastic resin reinforcing sheet materials laminated. And a process for producing a thermoplastic resin multilayer reinforcing sheet material. The thermoplastic resin multilayer reinforcing sheet material according to claim 19, wherein, in the laminating step, the thermoplastic resin reinforcing sheet material is laminated and laminated so that directions in which the reinforcing fibers are aligned are multiaxial. Manufacturing method. In the integration step, the laminated thermoplastic resin reinforcing sheet material is heated or heated and pressurized at a temperature at which the adhesive thermoplastic resin material melts or softens, and the laminated thermoplastic resin reinforcing sheet material is used. The method for producing a thermoplastic resin multilayer reinforcing sheet material according to claim 19 or 20, wherein the thermoplastic resin material for bonding is integrated by bonding with the thermoplastic resin material for bonding. In the integration step, the laminated thermoplastic resin reinforcing sheet material is partially heated or heated and pressurized at a temperature at which the adhesive thermoplastic resin material melts or softens, and the laminated thermoplastic resin reinforcement is obtained. The method for producing a thermoplastic resin multilayer reinforced sheet material according to claim 19 or 20, wherein the sheet material is partially bonded and integrated by the thermoplastic resin material for bonding. In the integration step, the laminated thermoplastic resin reinforcing sheet material is stitched and integrated by stitching with the thermoplastic resin fiber bundle for integration which is the same material as the thermoplastic resin sheet material. The manufacturing method of the thermoplastic resin multilayer reinforcement sheet material of Claim 19 or 20.