Search

JP-7855263-B2 - PP-FRP member and method for manufacturing the same

JP7855263B2JP 7855263 B2JP7855263 B2JP 7855263B2JP-7855263-B2

Inventors

  • 渡邊 泰
  • 城野 秀治

Assignees

  • ＡＲＴ＆ＴＥＣＨ株式会社

Dates

Publication Date
20260508
Application Date
20231013
Priority Date
20221014

Claims (9)

  1. The invention comprises a sheet-like textile and a plurality of composite layers having polypropylene impregnated and fixed within the mesh of the textile, The aforementioned multiple composite layers are laminated, and the polypropylene is filled and integrated within the mesh of the textile. The PP-FRP member is characterized in that the polypropylene contains 5 wt% to 30 wt% of tackifier, and the melting point of the polypropylene is 155°C or lower.
  2. The PP-FRP member according to claim 1, characterized in that the textile constituting any of the plurality of composite layers is a nonwoven fabric.
  3. The PP-FRP member according to claim 1, characterized in that one of the textiles constituting adjacent composite layers among the plurality of composite layers is a nonwoven fabric and the other is a woven fabric.
  4. The PP-FRP member according to any one of claims 1 to 3, further comprising a conductive material provided between the adjacent plurality of composite layers of the textile.
  5. (delete)
  6. (delete)
  7. The PP-FRP member according to any one of claims 1 to 3, characterized in that when the polypropylene is hot-pressed at a temperature between its softening point and melting point, between 100°C and 150°C, and at a pressure of 2.5 MPa or less, the rate of change in length before and after the hot-pressing is 1% or less.
  8. A step of stacking a plurality of prepreg sheets having a nonwoven fabric and polypropylene impregnated in the nonwoven fabric to form a first superimposed body, The process includes a step of hot-pressing the first superimposed material at a temperature of 100°C to 150°C, which is above the softening point and below the melting point of the polypropylene, and at a pressure of 1.5 MPa to 2.5 MPa. A method for producing a PP-FRP member, characterized in that the polypropylene contains 5 wt% to 30 wt% of tackifier, and the melting point of the polypropylene is 155°C or lower.
  9. A step of forming a second layered body by alternately layering a plurality of prepreg sheets having a woven fabric and polypropylene impregnated in the woven fabric, and a sheet-like textile, The process includes a step of hot-pressing the second superimposed material at a temperature of 100°C to 150°C, which is above the softening point and below the melting point of the polypropylene, and at a pressure of 1.5 MPa to 2.5 MPa. A method for producing a PP-FRP member, characterized in that the polypropylene contains 5 wt% to 30 wt% of tackifier, and the melting point of the polypropylene is 155°C or lower.

Description

This invention relates to a PP-FRP (Fiber Reinforced Plastics) member and a method for manufacturing the same. Conventionally, a method of producing components by impregnating resin into fibers is known as a resin decorative molding technique (for example, Patent Documents 1 and 2). For example, PVB (polyvinyl butyral) is used as the resin impregnated in this process. Components in which the resin and fiber layer are integrated possess sufficient strength. In such components, the injection-molded base resin layer is also fixed while impregnating into the gaps between each fiber of the nonwoven fabric layer. In the housing described in Patent Document 1, a nonwoven fabric layer is bonded to a decorative layer via an adhesive resin layer. The adhesive resin layer uses, for example, PVB (polyvinyl butyral) having a viscosity sufficient to allow air bubbles within the adhesive resin layer to escape through softening. Patent Document 1 also discloses that polypropylene is used as an example of the material for the base resin layer constituting the housing, and that the adhesive resin layer contains a conductive wire. Patent Document 2 discloses a veneer sheet and its application products in which a nonwoven fabric mainly composed of fibers capable of maintaining its shape at a temperature higher than the melting point of the resin film is interposed between the back surface of the veneer and the resin film, thereby configuring the resin film to be like FRP. Examples of nonwoven fabrics include PET fiber, and examples of resin films include propylene film. In the veneer sheet described in Patent Document 2, the nonwoven fabric and the base resin are firmly bonded together by creating an anchoring effect between them. Japanese Patent Publication No. 2020-175641Re-table 2013-190839 publication This is a cross-sectional view showing a PP-FRP member.(a) to (c) are cross-sectional views showing the prepreg manufacturing process.This is a perspective view showing the process of stacking prepregs and heat-pressing them together.(a) to (d) are cross-sectional views showing the molding and trimming processes, respectively.This is a perspective view showing the process of heat-pressing prepreg and textile together.(a) and (b) are cross-sectional views showing PP-FRP members with embedded wires and elements, respectively.This is a microscopic image of the cross-section. The inventors of the present invention, through repeated trial and error, have produced a PP-FRP member by layering prepregs, which are made by impregnating and fixing polypropylene onto a sheet-like nonwoven fabric, and joining them by heat compression, thus arriving at the present invention. By continuously layering polypropylene, which is impregnated and fixed into the mesh of the nonwoven fabric, the laminate can be strongly integrated while maintaining shape stability. Embodiments of the present invention will be described in detail below with reference to the drawings. [First Embodiment] [Structure of PP-FRP member] Figure 1 is a cross-sectional view showing the PP-FRP member 100. The configuration shown in Figure 1 is an example, and the PP-FRP member 100 is composed of composite layers 111 to 114. The composite layers 111 to 114 are laminated, and each of the composite layers 111 to 114 is made of polypropylene that has permeated and fixed into the textile and the mesh of the textile. In composite layers 111 to 114, polypropylene is continuously present across layers and permeates into the mesh of the textile. Due to the anchoring effect of the permeated polypropylene, each of the composite layers 111 to 114 is firmly bonded to the adjacent layer. In this way, a firmly integrated plate-like member is formed. The polypropylene preferably contains 5 wt% to 30 wt% of a tackifier. The tackifier is a tackifying resin, and for example, a petroleum-based one is used. This facilitates the preparation of the prepreg by hot melting. High-melting-point polypropylene can be used. Such high-melting-point polypropylene is a high-shrinkage type material and can be used as a component for products requiring a high modulus of elasticity. For example, high-melting-point polypropylene with a melting point of 150°C or higher is preferred. Such high-melting-point polypropylene is preferably composed of 85 wt% to 95 wt% polypropylene and 5 wt% to 15 wt% tackifier. Furthermore, low-melting-point polypropylene can also be used. Such low-melting-point polypropylene is a low-shrinkage type and is slightly softer than high-melting-point polypropylene. It can be used for impregnation into synthetic fiber fabrics with low heat resistance temperatures, such as polyethylene-reinforced fibers. As for low-melting-point polypropylene, for example, those with a melting point of 100°C or less are preferred. Such low-melting-point polypropylene is preferably composed of 70 wt% to 85 wt% of polypropylene and 15 wt% to 30 wt% of tackifier. The melting point of polypropylene is preferably