KR20060117677A - Thermoplastic compound sheet having high rigidity and the method for making the same - Google Patents

Abstract

A thermoplastic compound sheet having high rigidity is provided to increase the combining force and prevent the peeling phenomenon by combining the reinforcing sheet at the thermoplastic resin fluidized-bed. A thermoplastic compound sheet(12) having high rigidity used for manufacturing parts for a vehicle structure such as a bumper and a sheet frame to have a thermoplastic resin fluidized-bed for molding the product by the press process laminates a reinforcing sheet(10) made of more than one organic and inorganic fibers of a glass fiber, a basalt fiber, a carbon fiber, and an aramid fiber at the surface of the fluidized-bed supplied as a plate by passing through an extruder(1), and passes the material laminated with the reinforcing sheet through a continuous press apparatus such as a double belt press machine to impregnate the thermoplastic resin.

Description

Thermoplastic compound sheet having high rigidity and the method for making the same

1 is a schematic view showing a manufacturing process of a high rigid thermoplastic composite sheet according to a first embodiment of the present invention.

FIG. 2 is a view schematically illustrating a layer structure of a high rigid thermoplastic composite sheet manufactured according to the manufacturing process of FIG. 1.

3 is a conceptual diagram illustrating that a thermoplastic resin film layer may be formed on a sheet for reinforcement of the high rigid thermoplastic composite sheet shown in FIG. 2.

Figure 4 is a schematic diagram showing a manufacturing process of a high rigid thermoplastic composite sheet according to a second embodiment of the present invention.

FIG. 5 is a view schematically illustrating a layer structure of a highly rigid thermoplastic composite sheet manufactured according to the manufacturing process of FIG. 4.

6 is a schematic view showing a manufacturing process of a high rigid thermoplastic composite sheet according to a third embodiment of the present invention.

FIG. 7 is a view schematically illustrating a layer structure of a highly rigid thermoplastic composite sheet manufactured according to the manufacturing process of FIG. 6.

Figure 8 is a conceptual diagram comparing the product forming process (a) and the conventional product molding process (b) using a high rigid thermoplastic composite sheet according to the present invention.

<Description of the symbols for the main parts of the drawings>

1: extruder 2: Ti-die

3: double belt press 4: cutting machine

5: loader 6: slot

7: oven 8: press

10: reinforcing sheet 11, 21, 31: polypropylene resin

12, 22, 32: Additive 13: glass fiber mat

14, 24, 34: Composite sheet 23: Glass fiber

33: glass fiber pellets

The present invention relates to a highly rigid thermoplastic composite sheet used in structural parts of a vehicle and a method of manufacturing the same. More specifically, glass fiber reinforcement is improved by using a reinforcing sheet having a woven structure as a reinforcing material. A thermoplastic composite sheet and a method of manufacturing the same.

In general, thermoplastic composites are excellent in light weight and rigidity, and are used in structural parts of vehicles such as bumpers and seat frames. Examples of widely used thermoplastic composite materials include glass mat thermoplastics (hereinafter referred to as 'glass mats'). GMT ') and long fiber-reinforced thermoplastics (LFT).

The technology of GMT is well known by patents of Quadrant of Switzerland or Azdel of USA. GMT has several layers of glass fiber mat and resin layer and partially unidirectional reinforcement. There are possible features.

However, GMT has a limitation in rigidity due to the nature of the process using the press molding method using fluidity, such as glass fiber mat should be used in a non-woven form. In some cases, in order to improve the rigidity of GMT, a method of laminating reinforcing sheets to GMT and molding them together during GMT press processing for product molding is used, but in this case, the fluidity of GMT decreases and molding by press Not only is it difficult to laminate the reinforcement, there is a problem that the peeling phenomenon occurs.

In addition, the bonding force between the reinforcement and the GMT depends on the temperature and pressure, but when the reinforcement is added separately during press molding, the temperature of the GMT is lowered to cause the peeling phenomenon, and the reinforcement and the GMT are combined only by the pressure of the press. The binding force is weak.

The technique for LFT is well known by German patents such as Dieffenbacher and US CPI. LFT has good flow because glass fiber is cut and mixed with resin. However, in addition to the problems in GMT mentioned above, there is a problem that the impact strength is weak and reinforcement in a specific direction is difficult.

The present invention has been proposed to solve such a problem, and uses a sheet for reinforcement such as a woven sheet, a unidirectional tape, or a braided sleeve when manufacturing a thermoplastic composite sheet such as GMT or LFT. The purpose of the present invention is to provide a glass fiber-reinforced thermoplastic composite sheet and a method of manufacturing the same, thereby improving rigidity and preventing peeling from occurring.

High-strength thermoplastic composite sheet according to the present invention for achieving the above object, the reinforcing sheet made of any one or more of the glass fibers, bazalt fibers, carbon fibers, aramid fibers of organic and inorganic fibers having a fluidized bed of thermoplastic resin The thermoplastic composite material laminated on the surface of the glass fiber reinforced thermoplastic composite material and laminated with the reinforcing sheet so that the thermoplastic resin is impregnated into the reinforcing sheet is passed through a continuous press device such as a double belt press, and is manufactured in a plate shape.

In this case, the reinforcing sheet may be used in the form of a sheet such as a woven sheet, a unidirectional tape, or a braided sleeve, and may be a glass fiber, a basalt fiber, Reinforcing fibers such as carbon fibers and aramid fibers are not used alone, but may be prepared by mixing thermoplastic fiber rovings with the reinforcing fibers. In addition, the weaving method may be different or directionality may be provided depending on the use.

The high-strength thermoplastic composite sheet thus prepared is put into an oven, heated, laminated to a press, and molded into a shape of a product. According to the present invention, the surface of the thermoplastic resin fluid layer is reinforced in the pre-pressing step for forming a product. Since the raw material is manufactured into a plate-like sheet using a high temperature and high pressure continuous press device such as a double belt press after laminating the sheet, the bonding force between the reinforcing sheet and the thermoplastic resin is not only strengthened, but also no peeling phenomenon occurs.

In the present description, fluidity refers to the property or tendency of the resin impregnated in the sheet to flow into the shape of the mold when the sheet is impregnated into the shape of the product after heating the sheet impregnated with the thermoplastic resin in an oven. . Fluidized bed refers to a layer having such a tendency, and in the present description, it refers to a GMT in which a glass fiber mat is laminated between an LFT or a fiber-reinforced composite material extruded in a plate shape in an extruder or a plate material extruded in an extruder. Shall be.

Hereinafter, with reference to the accompanying drawings looks at the high rigid thermoplastic composite sheet according to a preferred embodiment of the present invention and a manufacturing method thereof.

As a high rigid thermoplastic composite sheet according to the present invention, a glass fiber mat thermoplastic composite (GMT) sheet, a long fiber reinforced composite (LFT) sheet, a fiber reinforced composite sheet will be described.

1 is a view illustrating a manufacturing process of a glass fiber mat thermoplastic composite (GMT) sheet 14, and as shown therein, the composite sheet 14 includes a polypropylene resin 11 and an additive ( 12) added and then heated and extruded by the extruder 1 to pass through the T-die 2 to be laminated in the form of a plate-like film, and unwinding the two glass fiber mats 13 And laminating so as to be disposed between the polypropylene resin layers 11 extruded from the extruder 1, and unwinding the reinforcing sheet 10 made of glass fibers on the surface of the laminate (ie, the fluidized bed). The step of laminating, and the step of continuous processing while applying the heat and pressure to the reinforcing sheet laminated material so that the reinforcing sheet 10 is impregnated with the molten polypropylene resin (11) using a double belt press (3) And the cutter-like material (4) is used for the plate-like material processed by the double belt press. And it is prepared by the steps of cutting into a predetermined size.

The cut composite sheet 14 is laminated to the laminator 5 and then heated in an oven (not shown) and press molded.

Here, the extruder 1 is a device used for kneading a normal thermoplastic resin, and the polypropylene resin 11 is mixed with the additive 12 and heat is applied to melt the polypropylene resin 11. The molten polypropylene resin 11 is extruded into a plate through the T-die 2.

In the above, only the double belt press 3 is mentioned, but in addition, a pressurization device or a continuous press device such as a calender or a polishing roll having a plurality of roller pairs may be used.

The additive 12 is added to improve the fluidity of the polypropylene resin 11 or to enhance the adhesion between the polypropylene 11 and the glass fiber mat 13 or to prevent oxidation, and is used in the manufacture of GMT. Is a known substance.

Figure 2 is a view showing the layer structure of the glass fiber mat thermoplastic composite (GMT) sheet produced through the above-mentioned manufacturing process, as shown in Figure 2, the glass fiber mat thermoplastic composite (GMT) sheet produced The reinforcing sheet 10 is laminated on the upper and lower surfaces of the fluidized layer in which two glass fiber mats 13 are laminated between three polypropylene resin layers 11.

As can be seen in Figure 3, in order to improve the impregnation of the polypropylene resin 11 with respect to the reinforcing sheet 10, the thermoplastic resin film layer 10a may be formed on the surface of the reinforcing sheet 10. . In this case, the thermoplastic film layer 10a is coated on the upper surface of the reinforcing sheet disposed above the fluidized layers 11 and 13 and the lower surface of the reinforcing sheet disposed below the fluidized layers 11 and 13, respectively. It is preferable to make the sheet | seat 10 laminated | stacked between thermoplastic resins. As a result, impregnation of the thermoplastic resin may occur at the upper and lower surfaces of the reinforcing sheet 10 when the double belt press 3 is processed.

FIG. 4 is a view illustrating a manufacturing process of a long fiber reinforced thermoplastic composite (LFT) sheet 24. As shown in FIG. 4, the manufacturing process of the composite sheet 24 may include a glass fiber mat thermoplastic composite (GMT) sheet. An apparatus similar to the apparatus used in the manufacturing process is used, and the configuration of the reinforcing sheet 10 is the same. Therefore, duplicate descriptions of the same matters are omitted.

The long fiber-reinforced thermoplastic composite sheet 24 incorporates a polypropylene resin 21, an additive 22, and a glass fiber 23 into the extruder 1, and heats and extrudes the extruder 1 through the extruder. Extruding from the extruder 1 by unwinding two reinforcing sheets 10 made of at least one of organic and inorganic fibers of at least one of glass fibers, basalt fibers, carbon fibers, and aramid fibers through extrusion through a plate. It is manufactured through the step of laminating on the upper and lower surfaces of the raw material (ie fluidized bed).

In general, the LFT is extruded in the form of a paste in the form of a plate in the extruder 1, and then press-molded into a product shape as it is, but in the present invention, the reinforcing sheet 10 is laminated on the upper and lower surfaces of the LFT fluid layer to prepare a sheet for press molding. . The process after the step of laminating the reinforcing sheet 10 is the same as the manufacturing process of the glass fiber mat thermoplastic composite (GMT) sheet.

FIG. 5 is a view showing a layer structure of the long fiber reinforced thermoplastic composite sheet 24 manufactured through such a manufacturing process. As shown in FIG. 5, the manufactured composite sheet 24 includes a polypropylene resin 21 and a polypropylene resin 21. The reinforcing sheet 10 is laminated on the upper and lower surfaces of the fluidized layer in which the glass fibers 23 are mixed.

6 is a view illustrating a manufacturing process of the composite sheet 34 using the fiber-reinforced thermoplastic pellets, as shown in the manufacturing process of the composite sheet 34 and also a manufacturing process of the glass fiber mat thermoplastic composite (GMT) sheet An apparatus similar to the apparatus used is used, and the reinforcing sheet 10 is the same. Therefore, duplicate descriptions of the same matters are omitted.

The fiber-reinforced thermoplastic composite sheet 34 is mixed with the glass fiber-reinforced pellet 33 alone or with the polypropylene resin 31 and the additive 32 in the extruder 1, and then heated and extruded with the extruder 1, Extruding the sheet through the die (2) and unwinding the two reinforcing sheets (10) made of at least one of organic and inorganic fibers of at least one of glass fibers, bazalt fibers, carbon fibers, and aramid fibers. It is produced through the step of laminating on the upper and lower surfaces of the material (that is, the fluidized bed) extruded from 1).

Typically, the fiber-reinforced thermoplastic composite is extrusion molded into a product shape immediately after being extruded from the extruder (1), but in the present invention is laminated to the upper and lower surfaces of the fiber-reinforced composite fluidized bed to produce a sheet for press molding . The process after the step of laminating the reinforcing sheet 10 is the same as the manufacturing process of the glass fiber mat thermoplastic composite (GMT) sheet.

FIG. 7 illustrates a layer structure of the fiber-reinforced thermoplastic composite sheet 34 manufactured through such a manufacturing process. As shown in FIG. 7, the manufactured composite sheet 34 is made of polypropylene resin 31 and glass. The reinforcing sheet 10 for reinforcement is laminated on the upper and lower surfaces of the fluidized bed in which the fibers 33 are mixed.

As can be seen in FIG. 8, the glass fiber reinforced thermoplastic composite sheet is heated in an oven 7 and then laminated to a press 8 to form a product.

As can be seen in Figure 8 (a), the conventional thermoplastic composite sheet 40 is put into the oven 7 alone and heated, and then laminated together with the reinforcing material 41 in the press 8 to press molding Therefore, the bonding force is weak and there was a problem of peeling.

However, since the composite sheet 14 according to the present invention is formed of a high rigid composite sheet using a double belt press of high temperature and high pressure after laminating the reinforcing sheet 10 on the surface of the thermoplastic resin fluidized layer 11, the fluidized layer 11, 13) and the bonding force between the reinforcing sheet 10 is strong. In addition, such a composite sheet, as can be seen in Figure 8 (b), since it is injected into the oven (7) as a single body is heated and then the press (8) is formed so that no peeling phenomenon occurs.

According to the high-strength thermoplastic composite sheet having a structure as described above and a manufacturing method thereof, since the reinforcing sheet having a woven structure of various forms is used as the reinforcing material, not only the rigidity of the composite sheet is improved, but also the thermoplastic composite sheet is formed before press molding. Since the reinforcing sheet is bonded to the thermoplastic resin fluidized layer in the manufacturing step, the bonding force is excellent, and peeling does not occur.

Claims (7)

In the manufacture of structural parts of a vehicle such as a bumper, a seat frame, a glass fiber reinforced thermoplastic composite sheet having a fluidized bed of thermoplastic resin for forming a product by press working, Laminate a reinforcing sheet made of at least one of glass fibers, bazalt fibers, carbon fibers and aramid fibers of organic and inorganic fibers on the surface of the fluidized bed supplied through the extruder, and the reinforcing sheets are laminated so that the thermoplastic resin is impregnated. A highly rigid thermoplastic composite sheet characterized in that the material is made into a plate by passing a continuous press device such as a double belt press. The method of claim 1, The reinforcing sheet is a high rigid thermoplastic composite sheet, characterized in that it comprises at least one of a woven sheet, a unidirectional tape, a braided sleeve. The method according to claim 1 or 2, On the surface of the reinforcing sheet, a thermoplastic resin film layer is formed in order to improve the impregnation of the thermoplastic resin. The method according to claim 1 or 2, The fluidized bed is a high-stiffness thermoplastic composite sheet, characterized in that the glass fiber mat thermoplastic composite (GMT) is a glass fiber mat laminated on a thermoplastic resin that is heated and extruded in an extruder and supplied into a plate. The method according to claim 1 or 2, The fluidized bed is a high-strength thermoplastic composite sheet characterized in that the long-fiber reinforced composite (LFT) is produced in the form of a plate by mixing the glass fiber in the thermoplastic resin heated and extruded in the extruder. The method according to claim 1 or 2, The fluidized bed is a high rigid thermoplastic composite sheet, characterized in that the fiber-reinforced composite is produced in a plate shape by mixing the glass fiber pellets in the thermoplastic resin is heated and extruded in the extruder. In the manufacturing method of a high rigid thermoplastic composite sheet having a fluidized bed of thermoplastic resin for forming a product by press working, which is used for manufacturing structural parts of a vehicle such as a bumper and a seat frame, Laminating the reinforcing sheet made of any one or more of glass fibers, carbon fibers, and aramid fibers and reinforcing sheets made of glass fibers, carbon fibers, and aramid fibers on the surface of the sheet-shaped fluidized bed supplied through an extruder; Continuously processing the material in which the reinforcing sheet is laminated so that the thermoplastic resin is impregnated into the reinforcing sheet while applying heat using a continuous press device such as a double belt press; And And cutting the plate-shaped material processed by the continuous press device into a predetermined size using a cutter.

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