Patent Application
20230053997
The present invention relates to a method for manufacturing a fiber-containing sheet and a fiber-containing sheet.
When plastic composite materials containing fiber materials such as carbon fiber and glass fiber in resin are molded, the fibers may become oriented along the flow direction (MD) of the molded product. The occurrence of this orientation is particularly characteristic of sheet extrusion using a T-die. The orientation along the MD causes the molded sheet to have improved strength in the direction along MD. The technology for forming such plastic composites containing fiber material using a T-die is described, for example, in JPH08-269210A.
However, sheets formed by this method and oriented along the MD have high strength in the direction along the MD as described above, but have low strength in the direction perpendicular to the MD (TD), and low strength in the direction perpendicular to the MD (TD).
As a countermeasure, multiple sheets oriented along MD are stacked at different angles to each other and integrated by heat press processing to obtain a sheet with strength in all directions. However, such a method requires special techniques for this purpose, forming time for this purpose, and costs for this purpose.
The purpose of the present invention is to solve these problems so that fiber-containing sheets with suppressed orientation can be obtained easily and reliably.
In order to achieve this purpose, the method for manufacturing a fiber-containing sheet of the present invention is based on the following method: In extruding resin into a sheet form using a T-die, performing the extrusion from the T-die with a first resin for forming a core layer and a second resin for forming both skin layers on both sides of the core layer laminated together, wherein the first resin contains fiber material and the second resin does not contain fiber material.
In detail, this invention was made based on the knowledge that the cause of fiber orientation in composite materials containing fibers in resin is that when the resin and fibers in a molten state flow through the T-die in a mixed state and are finally stretched into a sheet in the T-die, the fibers are oriented in the direction along the MD due to the resistance of the channel surface. According to the present invention, in extrusion molding using a T-die, skin layers are placed on both sides of the core layer, the core layer is molded with resin containing fiber material, and both skin layers are molded with resin not containing fiber material. The resin containing fiber material in the core layer is extruded from the T-die so that it does not contact the surfaces of the flow channel of the T-die, and thus the resin is formed into a sheet with reduced fiber orientation.
According to the method for manufacturing the fiber-containing sheet of the present invention, it is suitable to mold the first resin of the core layer and the second resin of both skin layers together in a peelable state. In this way, the skin layer can be peeled off from the core layer after molding to obtain a sheet with fiber-containing resin with suppressed orientation exposed on the surface.
According to the method for manufacturing the fiber-containing sheet of the present invention, in order to achieve good separation of the first resin for the core layer from the second resin for both skin layers, it is suitable to use the first and second resins that are incompatible with each other.
According to the method for manufacturing the fiber-containing sheet of the present invention, by peeling off at least one of the skin layers from the molded body obtained in an integrally laminated state, it is easy to obtain a sheet in which the fiber-containing resin whose orientation is suppressed exposes on the surface of the sheet.
According to the method for manufacturing the fiber-containing sheet of the present invention, it is also suitable to mold the first resin of the core layer and the second resin of both skin layers in one piece in a state where they cannot be peeled off from each other. In this way, a fiber-containing sheet with suppressed orientation can be easily obtained without conducting a peeling process.
According to the method for manufacturing the fiber-containing sheet of the present invention, it is also suitable to use resins that are compatible with each other as the first resin for forming the core layer and the second resin for forming both skin layers. In this way, the first resin for the core layer and the second resin for both skin layers can be easily molded together in a manner that they cannot be peeled off from each other.
The fiber-containing sheet according to the present invention comprises a core layer made of a first resin containing fiber material and skin layers made of a second resin not containing fiber material and disposed on both sides of the core layer. The skin layer is peelable to the core layer.
Other fiber-containing sheet according to the present invention comprises a first resin core layer containing fiber material and second resin skin layers, and the first resin core layer and second resin skin layers are molded in one piece, in which the second resin skin layers are disposed on both sides of this core layer and does not contain fiber material.
According to the present invention, it is possible to easily and reliably obtain a fiber-containing sheet in which orientation is suppressed.
The detailed structure of a T-die shown in
The feed block 13 has a first path 14 that supplies a fiber-containing resin material in a molten state for the core layer, and a pair of second paths 15 and 15 that supply another molten resin material for the skin layer. At the confluence 16, the molten state resin materials from the respective paths 14, 15, and 15 are merged. A first molten state fiber-containing resin material for the skin layer from the second paths 15 and 15 is fed to both sides of a second molten state fiber-containing resin material for the core layer from the first path 14. As a result, these molten state resin materials are fed to the die 12 in three layers.
The die 12 has a narrow nozzle 18, which is formed long and narrow in the direction perpendicular to the plane of
In the T-die 11 shown in
In the manufacturing method of the present invention, the T-die 11 is not limited to the above configuration, and any configuration can be used as long as it is capable of extruding a sheet with a laminated structure in which skin layers are arranged on both sides of the core layer.
For example, although not shown in
According to the present invention, using the T-die 11 in the configuration shown in
The core layer 25 is composed of fiber material 28 in resin 27. In contrast, the skin layers 26 and 26 are composed of no fiber material in the resin.
Any thermoplastic resin can be suitably used as the resin forming the core layer 25, as long as it can be extruded from the T-die 11 in a molten state. For example, polyolefins such as polyethylene and polypropylene, polyamide, polyester, polycarbonate, polystyrene, polylactic acid, polyvinyl chloride, liquid crystal polymer, polyphenylene sulfide, poly(ether-ether-ketone), and polyetherimide can be used. Fiber material 28 is added primarily to reinforce resin 27, and any fiber material can be suitably used as long as it can achieve that purpose. For example, carbon fiber, glass fiber, boron fiber, high-strength resin fiber, cellulose fiber, etc. can be mentioned.
As mentioned above, the skin layers 26, 26 are formed in contact with both sides of the core layer 25, respectively. The resins comprising the skin layers 26, 26 can be resins that are incompatible with the resins comprising the core layer 25 or resins that are compatible with the resins comprising the core layer 25. When the resin comprising the skin layers 26, 26 is a resin that is incompatible with the resin comprising the core layer 25, as shown by the virtual line in
An example of a combination of compatible resins is, for example, when the resin comprising the core layer 25 and the resins comprising the skin layers 26, 26 are the same type of resin, such as both being polypropylene. The combination of incompatible resins is, for example, a case where the resin comprising the core layer 25 is polypropylene and the resins comprising the skin layers 26, 26 are high-density polyethylene. Another example is such that resin comprising the core layer 25 is polypropylene and the resin comprising the skin layers 26, 26 is polycarbonate.
When molding the molding body shown in
The skin layers 26 and 26 prevent the resin comprising the core layer 25 from contacting the surfaces of the resin channel when the resin flows along the resin channel in the T-die 11 in a molten state. Therefore, it is sufficient that the skin layers 26, 26 have the minimum thickness necessary to fulfill their function. For example, the skin layer 26 is effective if it is at least 10 μm thick. However, there is a problem that interlayer turbulence (flow marks) occurs between 10 and 50 μm and that the orientation of the fiber material 28 is not controlled. Therefore, a skin layer thickness of 50 μm or more is recommended. The total thickness of the core layer 25 and the pair of skin layers 26, 26 can be set appropriately according to the application of the molded product.
As described above, it is sufficient that the skin layers 26, 26 prevent the resin comprising the core layer 25 from contacting the surfaces of the resin channel when the resin flows along the resin channel in the T-die 11 in a molten state. Therefore, in principle, the skin layers 26, 26 should not contain fiber material, but as long as it is possible to prevent the fiber material from being oriented in the core layer 25. However, as long as the orientation of the fiber material in the core layer 25 can be prevented, it is acceptable if the skin layers 26, 26 contain some fiber material. In the present invention, the fact that skin layers 26 and 26 do not contain fiber material in the resin means that they broadly include up to such cases.
In the following examples and comparative examples, each physical property was measured as follows.
The molten resin discharged from two extruders (Hitachi Zosen: HMT57, SHT65), one for the core layer and the other for the skin layer, was laminated in a feed block (Hitachi Zosen: FB 3), and then laminated in a T-die (Hitachi Zosen: TFS102F), and then stretched to a width of 1020 mm in a T-die (Hitachi Zosen: TFS102F), and then formed into sheets using a sheet forming machine (Hitachi Zosen: GOMP120.3). The sheet was formed by being compressed between rolls of the sheet forming machine and then solidified. The formed sheet was cut to 1 m in length, and a 30 mm square piece was cut from the formed sheet. The surface of the 30 mm square piece was examined under an optical microscope (Keyence: VHX-900) to visually observed the orientation.
The peelability was checked by making a cut in a part of the skin layer with a sharp blade such as a cutter knife, and then the skin layer on one side and the skin layer on the other side, where the cut was made to trigger the peeling, were manually grabbed. The peelability was then inspected by manually pulling both of the skin layers in different directions to peel them off.
Polypropylene resin containing 30 mass % carbon fiber (product name and number: Pyrophil PP-C-30, manufactured by Mitsubishi Chemical) was used as the material for the core layer. Polypropylene resin (product number: EA-9, manufactured by Nippon Polypro) was used as the material for both skin layers. Then, using a T-die with the structure shown in
The resulting molded body had the core layer and skin layer firmly integrated, and the two could not be peeled off by the method described above. Microscopic observation of the surface of the core layer from the surface of the skin layer showed that there was no noticeable directionality in the orientation of the carbon fibers, and it could be said that the carbon fibers were randomly oriented.
Table 1 shows the manufacturing conditions and measurement results of the physical properties of Example 1.
Compared to Example 1, the manufacturing conditions were changed as shown in Table 1. Other conditions were the same as in Example 1.
The manufacturing conditions and measurement results of physical properties for Examples 2-4 are shown in Table 1.
Compared to Example 4, the material used to construct the skin layer was changed to high-density polyethylene (product number: HF3-13, manufactured by Nippon Polypro), which is incompatible with the resin used to construct the core layer. The rest of the process was the same as in Example 4.
The manufacturing conditions and measurement results of physical properties for Example 5 are shown in Table 1.
Compared to Example 3, the materials used to construct the skin layer were changed as follows. In detail, a material blended with the above-mentioned polypropylene and above-mentioned high-density polyethylene in a mass ratio of polypropylene: high-density polyethylene=2:1 was used as the material to constitute the skin layer. The rest of the process was the same as in Example 3.
The manufacturing conditions and measurement results of physical properties for Example 6 are shown in Table 1.
Compared to Example 3, the material used to compose the skin layer was changed to polycarbonate resin (product number: E-2000, manufactured by Mitsubishi Engineering-Plastics) was used to construct the skin layer. The rest of the process was the same as in Example 3.
The manufacturing conditions and measurement results of physical properties for Example 7 are shown in Table 1.
A sheet-like molded body without a skin layer was obtained using only the materials used to construct the core layer in Example 1.
The manufacturing conditions and measurement results of physical properties for Comparative Example 1 are shown in Table 1.
As shown in Table 1, in all of the sheet-like molded bodies of Examples 1 through 7, no noticeable directionality was observed in the orientation of the carbon fibers, and the carbon fibers were randomly oriented. In contrast, in Comparative Example 1, the carbon fibers in the resin in the molded body were strongly oriented in the direction along the MD, because the body was molded without the material used to constitute the skin layer.
In Examples 1-4 and 6, the material used to construct the core layer and the material used to construct the skin layer were of the same type and compatible with each other, so that the skin layer and the core layer were tightly integrated. On the other hand, in Examples 5 and 7, the materials for the core layer and the material for the skin layer were different and incompatible with each other, so the skin layer could be easily peeled from the core layer after molding. As a result, it was possible to construct a sheet-like molded body only by the material containing fiber material in the resin.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-022080 | Feb 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/002732 | 1/27/2021 | WO |
