Reinforced thermoplastic-resin multilayer sheet material

Abstract

A high-quality multilayer thermoplastic-resin-reinforced sheet material having excellent mechanical properties and drapeability in which a thermoplastic resin excellent in recycling efficiency and shock resistance is used as a matrix. A thermoplastic-resin multilayer reinforced molding formed of the multilayer thermoplastic-resin-reinforced sheet material, in which the high quality and the mechanical properties are maintained. The multilayer thermoplastic-resin-reinforced sheet material (11) is formed by stacking thermoplastic-resin-reinforced sheet materials (21A) to (21D) each formed of a reinforcing-fiber sheet material (31), consisting of a plurality of reinforcing fibers (31f) arranged in a predetermined direction in a sheet-like structure, and a thermoplastic-resin sheet material (41) joined to a surface of the reinforcing-fiber sheet material (31), and stitching them together with an integration thermoplastic-resin fiber tow (51) composed of the same material as the thermoplastic-resin sheet material (41). The reinforcing-fiber sheet materials (31) are stacked such that their reinforcing directions are multiaxial.

Claims

1. A thermoplastic-resin-reinforced sheet material formed by joining a reinforcing-fiber sheet material, including a plurality of reinforcing fibers arranged in a predetermined direction, to both surfaces of a thermoplastic-resin sheet, wherein a material of the thermoplastic-resin sheet serves as matrix, only a surface layer portion of the reinforcing-fiber sheet material being impregnated with the material of the thermoplastic-resin sheet, wherein the cross-sectional thickness of the reinforcing-fiber sheet material is set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber, wherein the thermoplastic-resin sheet is bonded to the entirety or several portions of one surface of the reinforcing-fiber sheet material by thermal adhesion, wherein the reinforcing-fiber sheet material is formed from multi-filament formed by continuously spreading, in a width direction, a reinforcing fiber tow including a plurality of filament-type reinforcing fibers bundled together, and wherein the reinforcing-fiber sheet material is formed of a plurality of reinforcing fiber tows, each including a plurality of reinforcing fibers bundled together with a sizing agent so as not to be unraveled, arranged in a sheet-like structure.

2. A thermoplastic-resin-reinforced sheet material formed of a plurality of narrow, having a width in a range of 1 mm-20 mm, thermoplastic-resin-reinforced sheet materials arranged in a width direction, the plurality of narrow, having a width in a range of 1 mm-20 mm, thermoplastic-resin-reinforced sheet materials each formed by joining a narrow, having a width in a range of 1 mm-20 mm, reinforcing-fiber sheet material, including a plurality of reinforcing fibers arranged in a predetermined direction, to both surfaces of a narrow, having a width in a range of 1 mm-20 mm, thermoplastic-resin sheet, wherein a material of the thermoplastic-resin sheet serves as matrix, only a surface layer portion of the reinforcing-fiber sheet material being impregnated with the material of the thermoplastic-resin sheet, wherein the cross-sectional thickness of each reinforcing-fiber sheet material is set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber, wherein the thermoplastic-resin sheet material is bonded to the entirety or several portions of one surface of the reinforcing-fiber sheet material by thermal adhesion, wherein the reinforcing-fiber sheet material is formed from multi-filament formed by continuously spreading, in a width direction, a reinforcing fiber tow including a plurality of filament-type reinforcing fibers bundled together, and wherein the reinforcing-fiber sheet material is formed of a plurality of reinforcing fiber tows, each including a plurality of reinforcing fibers bundled together with a sizing agent so as not to be unraveled, arranged in a sheet-like structure.

3. A thermoplastic-resin-reinforced sheet material formed by weaving a narrow, having a width in a range of 1 mm-20 mm, thermoplastic-resin-reinforced sheet material formed by joining a narrow, having a width in a range of 1 mm-20 mm, reinforcing-fiber sheet material, including a plurality of reinforcing fibers arranged in a predetermined direction, to both surfaces of a narrow, having a width in a range of 1 mm-20 mm, thermoplastic-resin sheet, wherein a material of the thermoplastic-resin sheet serves as matrix, only a surface layer portion of the reinforcing-fiber sheet material being impregnated with the material of the thermoplastic-resin sheet, wherein the cross-sectional thickness of the reinforcing-fiber sheet material is set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber, wherein the thermoplastic-resin sheet material is bonded to the entirety or several portions of one surface of the reinforcing-fiber sheet material by thermal adhesion, wherein the reinforcing-fiber sheet material is formed from multi-filament formed by continuously spreading, in a width direction, a reinforcing fiber tow including a plurality of filament-type reinforcing fibers bundled together, and wherein the reinforcing-fiber sheet material is formed of a plurality of reinforcing fiber tows, each including a plurality of reinforcing fibers bundled together with a sizing agent so as not to be unraveled, arranged in a sheet-like structure.

4. The thermoplastic-resin-reinforced sheet material of claim 1, wherein the cross-sectional thickness of each reinforcing-fiber sheet material being set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber is configured to control a distance over which a thermoplastic resin flows between the plurality of reinforcing fibers.

5. The thermoplastic-resin-reinforced sheet material of claim 2, wherein the cross-sectional thickness of each reinforcing-fiber sheet material being set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber is configured to control a distance over which a thermoplastic resin flows between the plurality of reinforcing fibers.

6. The thermoplastic-resin-reinforced sheet material of claim 3, wherein the cross-sectional thickness of each reinforcing-fiber sheet material being set greater than two times the diameter of each reinforcing fiber and set within ten times the diameter of each reinforcing fiber is configured to control a distance over which a thermoplastic resin flows between the plurality of reinforcing fibers.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic view showing a multilayer thermoplastic-resin-reinforced sheet material according to an embodiment of the present invention.

(2) FIG. 2 is a schematic view showing a wide thermoplastic-resin-reinforced sheet material.

(3) FIG. 3 is a schematic view showing another wide thermoplastic-resin-reinforced sheet material.

(4) FIG. 4 is a schematic view showing a thermoplastic-resin-reinforced sheet material obtained by arranging narrow thermoplastic-resin-reinforced sheet materials in a width direction.

(5) FIG. 5 is a schematic view showing another thermoplastic-resin-reinforced sheet material used in an embodiment of the present invention.

(6) FIG. 6 is a schematic view showing another thermoplastic-resin-reinforced sheet material used in an embodiment of the present invention.

(7) FIG. 7 is a schematic view showing a thermoplastic-resin-reinforced sheet material obtained by arranging another narrow thermoplastic-resin-reinforced sheet materials in the width direction.

(8) FIG. 8 is a schematic view showing a multilayer thermoplastic-resin-reinforced sheet material in which thermoplastic-resin-reinforced sheet materials are stacked and bonded together.

(9) FIG. 9 is an explanatory diagram related to a method for producing a thermoplastic-resin-reinforced sheet material.

(10) FIG. 10 is an explanatory diagram related to a method for producing another thermoplastic-resin-reinforced sheet material.

(11) FIG. 11 is an explanatory diagram related to a method for producing another thermoplastic-resin-reinforced sheet material.

(12) FIG. 12 is an explanatory diagram related to a method for producing another thermoplastic-resin-reinforced sheet material.

(13) FIG. 13 is an explanatory diagram related to a method for producing another thermoplastic-resin-reinforced sheet material.

(14) FIG. 14 is an explanatory diagram related to a method for producing a multilayer thermoplastic-resin-reinforced sheet material using a thermoplastic-resin-reinforced sheet material.

(15) FIG. 15 is an explanatory diagram related to a method for producing a plurality of narrow thermoplastic-resin-reinforced sheet materials from a wide thermoplastic-resin-reinforced sheet material.

(16) FIG. 16 is an explanatory diagram related to a method for producing a plurality of narrow thermoplastic-resin-reinforced sheet materials from a wide thermoplastic-resin-reinforced sheet material and winding them on bobbins.

(17) FIG. 17 is an explanatory diagram related to a method for producing a multilayer thermoplastic-resin-reinforced sheet material from narrow thermoplastic-resin-reinforced sheet materials.

(18) FIG. 18 is an explanatory diagram related to a production method in which a plurality of stacked thermoplastic-resin-reinforced sheet materials are subjected to heat and pressure to be bonded together.

(19) FIG. 19 is an explanatory diagram related to surface shapes of a heating roll.

(20) FIG. 20 is an explanatory diagram related to a method for producing thermoplastic-resin multilayer reinforced molding.

(21) FIG. 21 is an explanatory diagram related to another method for producing a thermoplastic-resin multilayer reinforced molding.

(22) FIG. 22 is a schematic cross-sectional view showing a state in which a molding material is set in shaping molds.

(23) FIG. 23 is a process explanatory diagram related to an embodiment of the present invention.

(24) FIG. 24 is a process explanatory diagram related to another embodiment of the present invention.

(25) FIG. 25 is a cross-sectional view showing a modification related to attachment of a seal member in FIG. 23.

(26) FIG. 26 is a process explanatory diagram related to yet another embodiment of the present invention.

REFERENCE NUMERALS

(27) A: thermoplastic-resin multilayer reinforced molding B: preformed laminate S1, S2: multi-filament spread thread 11, 12: multilayer thermoplastic-resin-reinforced sheet material 21, 22: thermoplastic-resin-reinforced sheet material 31, 32: reinforcing-fiber sheet material 41, 42: thermoplastic-resin sheet material 51: integration thermoplastic-resin fiber tow 52: bonding thermoplastic-resin material 61, 62: release film 90: hot press molding apparatus 91: shaping upper metal mold 92: shaping lower metal mold 93: flat upper metal mold 94: flat lower metal mold 96: heating unit 100, 101, 111: shaping mold 102: gas-discharging space 103: hot press 106: cold press 109: tube 110: seal member 200, 300: thermoplastic-resin-reinforced sheet material producing apparatus 400: sheet-type multilayer thermoplastic-resin-reinforced sheet material producing apparatus 500: narrow thermoplastic-resin-reinforced sheet material producing apparatus 600: narrow-sheet-type multilayer thermoplastic-resin-reinforced sheet material producing apparatus 700: heat-integration mechanism