JP7609407B2 - Laminated composite material and method for manufacturing the laminated composite material - Google Patents

Description

The present invention relates to a laminated composite material comprising a carbon fiber fabric and a method for producing the laminated composite material.

Carbon fiber reinforced plastics (CFRP) have low density yet high strength compared to metal materials, and therefore are widely used as structural materials in various fields, although they have the problem of high manufacturing costs.
Conventional techniques relating to such carbon fiber reinforced plastics are disclosed in Patent Documents 1 to 3.

Japanese Patent Application Publication No. 02-169633 Japanese Patent Application Publication No. 10-138354 JP 2013-202923 A

Carbon fiber reinforced plastics have come to be used based on their mechanical properties of being lightweight yet strong, but they are now also being used for their design potential. That is, the patterns that appear when the carbon fibers are woven are used for design purposes.
As a result of this increased emphasis on design-related uses, there is a demand for a greater variety of materials, such as materials with different characteristics while still having the design quality of carbon fiber reinforced plastics.

In view of the above, the present invention aims to provide a new laminated composite material that includes carbon fiber fabric and is not available in the past, and to provide a method for manufacturing the laminated composite material.

(Configuration 1)
A laminated composite material comprising: a carbon fiber fabric woven from carbon fibers; and a thermoplastic resin sheet having elastomeric properties that is heat-compressed to the upper and lower surfaces of the carbon fiber fabric.

(Configuration 2)
2. The laminated composite material according to claim 1, wherein the thermoplastic resin sheet is translucent.

(Configuration 3)
3. The laminated composite material according to claim 1 or 2, wherein the thermoplastic resin sheet is a polyurethane sheet.

(Configuration 4)
4. The laminated composite material according to any one of claims 1 to 3, wherein the thermoplastic resin sheet has a thickness greater than that of the carbon fiber fabric.

(Configuration 5)
A laminated composite material according to any one of configurations 1 to 3, characterized in that one of the thermoplastic resin sheets heat-pressed to the upper and lower surfaces of the carbon fiber fabric has a thickness thinner than the carbon fiber fabric, and the other has a thickness thicker than the carbon fiber fabric.

(Configuration 6)
6. A laminated composite material according to any one of claims 1 to 5, characterized in that the surface of the thermoplastic resin sheet has a coating layer having a thickness thinner than the surface roughness Rz of the thermoplastic resin sheet.

(Configuration 7)
7. The laminated composite material according to claim 6, wherein the coating layer is formed of an antistatic agent or a water repellent agent.

(Configuration 8)
8. The laminated composite material according to claim 6 or 7, wherein the coating layer is formed from a fluororesin.

(Configuration 9)
9. The laminated composite material of any one of claims 1 to 8, further comprising a foamed ABS resin layer.

(Configuration 10)
The laminated composite material according to configuration 9, characterized in that the number of layers of the carbon fiber fabric on the upper and lower sides of the foamed ABS resin layer is the same.

(Configuration 11)
11. The laminated composite material according to claim 10, wherein the number of layers of the thermoplastic resin sheet and the carbon fiber fabric on the upper and lower sides of the foamed ABS resin layer is the same.

(Configuration 12)
A laminated composite material comprising: a foamed ABS resin layer; and a carbon fiber reinforced plastic layer heat-pressed to the foamed ABS resin layer.

(Configuration 13)
13. The laminated composite material according to claim 12, wherein the carbon fiber reinforced plastic layers are formed on both sides of the foamed ABS resin layer.

(Configuration 14)
14. The laminated composite material according to claim 13, wherein the number of laminations of the carbon fiber reinforced plastic layers on the upper surface side and the lower surface side of the foamed ABS resin layer is the same.

(Configuration 15)
15. The laminated composite material according to any one of configurations 12 to 14, wherein a thermoplastic resin layer is formed between the foamed ABS resin layer and the carbon fiber reinforced plastic layer.

(Configuration 16)
16. A laminated composite material according to any one of configurations 12 to 15, characterized in that a thermoplastic resin layer is formed on a surface of the carbon fiber reinforced plastic layer.

(Configuration 17)
17. The laminated composite material according to claim 15, wherein the number of layers of the thermoplastic resin layer and the carbon fiber reinforced plastic layer on the upper and lower sides of the foamed ABS resin layer is the same.

(Configuration 18)
5. A method for producing a laminated composite material according to any one of configurations 1 to 4, comprising the steps of: laminating, on a molding die, a first release sheet, a first thermoplastic resin sheet having elastomeric properties, the carbon fiber fabric, a second thermoplastic resin sheet having elastomeric properties, and a second release sheet; and thermocompression bonding the first and second thermoplastic resin sheets to the carbon fiber fabric.

(Configuration 19)
6. A method for producing a laminated composite material according to configuration 5, comprising the steps of: laminating, on a molding die, a release sheet, a thermoplastic resin sheet having elastomeric properties and being thicker than the carbon fiber fabric, the carbon fiber fabric, and a thermoplastic resin sheet having elastomeric properties and being thinner than the carbon fiber fabric, such that the release sheet and the thermoplastic resin sheet thicker than the carbon fiber fabric are in contact with each other; and thermocompression bonding the thermoplastic resin sheet to the carbon fiber fabric.

(Configuration 20)
The method for producing a laminated composite material according to configuration 14 or 15, characterized in that the first and second release sheets are pre-attached to the thermoplastic resin sheet, or the release sheet is pre-attached to the thermoplastic resin sheet.

(Configuration 21)
1. A method for producing a laminated composite material having at least a carbon fiber fabric layer, a thermoplastic resin layer, and a foamed ABS resin layer, comprising the steps of: preparing the foamed ABS resin layer as an ABS resin molded product; laminating, to the ABS resin molded product, a release sheet and a laminated sheet body having a carbon fiber fabric with a thermoplastic resin sheet laminated on at least one surface thereof, so that the release sheet and the thermoplastic resin sheet are in contact with each other; and thermocompression bonding the ABS resin molded product obtained by laminating the sheets together.

(Configuration 22)
1. A method for producing a laminated composite material having at least a carbon fiber reinforced plastic layer and a foamed ABS resin layer, comprising the steps of: preparing the foamed ABS resin layer as an ABS resin molded product; laminating a carbon prepreg onto the ABS resin molded product and laminating a release sheet onto the carbon prepreg to form a laminate; and thermocompression bonding the laminate together.

(Configuration 23)
23. The method for producing a laminated composite material according to any one of configurations 18 to 22, wherein the surface roughness Ra of the first and second release sheets or the release sheet is 0.5 μm to 1.0 μm.

The laminated composite material and manufacturing method thereof of the present invention provide a new laminated composite material and manufacturing method thereof that have not previously existed.

FIG. 1 is a schematic diagram showing a laminate structure of a laminated composite material according to a first embodiment of the present invention. FIG. 1 is an explanatory diagram showing a method for producing a laminated composite material according to a first embodiment of the present invention; FIG. 1 shows a bag in which the laminated composite material of the first embodiment is used. FIG. 1 is a schematic diagram showing a laminate structure of another example of the laminated composite material of embodiment 1. FIG. 1 is an explanatory diagram showing another example of a manufacturing method for the laminated composite material of the first embodiment. FIG. 1 is a schematic diagram showing a laminate structure of another example of the laminated composite material of embodiment 1. FIG. 1 is an explanatory diagram of a coating layer of a laminated composite material according to a second embodiment. Schematic diagram showing a laminate structure of a laminated composite material according to a third embodiment. Schematic diagram showing a laminate structure of a laminated composite material according to a fourth embodiment. FIG. 1 is a schematic diagram showing a stack structure of another example of a laminated composite material.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. Note that the following embodiment is one form for realizing the present invention, and does not limit the scope of the present invention.

<Embodiment 1>
This embodiment relates to a new laminated composite material containing a carbon fiber fabric, and will be described using a belt (a belt used in a bag) as a specific example of a molded product using the laminated composite material.
Bag 100 (see FIG. 3) is a travel case in which lid portion 11 and storage portion 12 are joined so as to be able to be opened and closed, and lid portion 11 and storage portion 12 are formed using a laminated composite material including carbon fiber reinforced plastic.

FIG. 1 is a schematic diagram showing the layered structure of a belt (laminated composite material) 1 according to the present embodiment.
The belt (laminated composite material) 1 of this embodiment is formed by thermoplastic resin sheets PU1 and PU2 having elastomeric properties being heat-pressed onto the upper and lower surfaces of a carbon fiber fabric CF woven from carbon fibers.
"Carbon fiber fabric woven from carbon fibers" means that there is no matrix resin (thermosetting resin) of the carbon prepreg.
In this embodiment, the thermoplastic resin sheet PU1 and the thermoplastic resin sheet PU2 are a 300 μm-thick translucent polyurethane sheet and a 150 μm-thick translucent polyurethane sheet. As shown in FIG. 3, the belt (laminated composite material) 1 is a belt used for a bag, and when attached to the bag, the front side is a design surface, and the back side is basically not a design surface. The belt (laminated composite material) 1 is provided with a 300 μm-thick thermoplastic resin sheet PU1 on the design surface side, and a 150 μm-thick thermoplastic resin sheet PU2 on the back side.
Since the thickness of the carbon fiber fabric CF is 200 μm, in the belt (laminated composite material) 1 of this embodiment, the thickness of the thermoplastic resin sheet PU1 is thicker than the carbon fiber fabric CF, and the thickness of the thermoplastic resin sheet PU2 is thinner than the carbon fiber fabric CF.

The laminated composite material, in which the translucent thermoplastic resin sheets PU1 and PU2 are thermocompression bonded to both sides of the carbon fiber fabric CF, is a very flexible material that feels like leather, and its surface appearance is similar to that of carbon material (carbon fiber reinforced plastic). In other words, it is a material that looks like carbon material but has a texture similar to leather, giving it a luxurious feel.
By forming belt 1 to be attached to bag 100 using the laminated composite material of this embodiment, it is possible to create a product with a more luxurious feel, matching the appearance of the carbon material of lid 11 and storage section 12. In addition to belt 1, the laminated composite material may also be used for each part used in bag 100 (each part that contacts the corners of lid 11 and storage section 12, handles, etc.).

Next, we will explain the manufacturing method of the laminated composite material of this embodiment.

As shown in Figure 2, a release sheet RP, a thermoplastic resin sheet PU1, a carbon fiber fabric CF, and a thermoplastic resin sheet PU2 are layered in this order on a molding die T. This results in "layering the release sheet, a thermoplastic resin sheet thicker than the carbon fiber fabric, the carbon fiber fabric, and a thermoplastic resin sheet thinner than the carbon fiber fabric, so that the release sheet and the thermoplastic resin sheet thicker than the carbon fiber fabric are in contact with each other on the molding die."

The forming mold T is simply a plate-like mold for stacking the individual sheets, but is made from a material with a similar linear expansion coefficient to that of carbon. Because the forming mold T is made from a material with a similar thermal expansion coefficient to that of carbon, the occurrence of wrinkles or shrinkage in the product due to the effects of temperature changes before and after thermocompression is reduced. Examples of materials with a similar thermal expansion coefficient to carbon include carbon plates and gypsum boards.

The release sheet RP is disposed between the thermoplastic resin sheet PU1 and the mold T to protect the surface of the thermoplastic resin sheet PU1 and to improve the design of that surface, and is made of heat-resistant paper.
Since the thermoplastic resin sheet PU1 is disposed on the side that contacts the mold T, even a slight scratch or the like on the mold T may be transferred to the surface of the thermoplastic resin sheet PU1 during thermocompression bonding. Also, if dust or dirt is attached to the mold T, the dust or dirt may similarly appear on the surface of the thermoplastic resin sheet PU1. By using the release sheet RP, such problems can be reduced.
In addition, by laminating the release sheet RP and the thermoplastic resin sheet PU1 and thermocompression bonding them, the fine unevenness on the surface of the release sheet RP is transferred, and a matte texture can be imparted to the surface (design surface) of the thermoplastic resin sheet PU1. This unevenness also has the effect of making the adhesion of dirt and scratches specific to thermoplastic resin less noticeable when the product is made. By using a release sheet RP with an arithmetic mean roughness Ra of 0.5 μm to 1.0 μm, a suitable matte texture can be formed on the surface of the first thermoplastic resin layer. The arithmetic mean roughness Ra is obtained by extracting a part of the roughness curve measured by a roughness meter over a reference length and expressing the unevenness of that section as an average value.
In addition, by using a sheet with a smooth surface as the release sheet RP, the surface of the thermoplastic resin layer can be made glossy.
In this manner, by using the release sheet RP, the surface of the thermoplastic resin sheet PU1 can be protected and the design of the surface can be improved.
In this embodiment, the release sheet RP is pre-cut and previously attached to the thermoplastic resin sheet PU1, and in the lamination process onto the molding die T, the release sheet RP and the thermoplastic resin sheet PU1 are handled as a single unit.

After stacking each sheet on the mold T as shown in Figure 2, the resultant is molded by thermocompression bonding using an autoclave process, and the molded product is demolded from the mold T to obtain a molded product formed from the laminated composite material of this embodiment.
For autoclave molding, various methods can be used as appropriate. Autoclave molding is a known technology, and will not be described here. However, during thermocompression bonding, it is preferable to maintain the vacuum in the bag containing the laminated composite material (maintain the compressed state) until the temperature drops to 80 degrees or less. This is because the laminated composite material of this embodiment uses a thermoplastic resin, and if the vacuum is relaxed at a temperature higher than 80 degrees, unevenness may occur in the transfer of the matte feel by the release paper RP.

The laminated composite material of this embodiment is a flexible material as described above, and can be appropriately processed by cutting, sewing, and the like.
Therefore, for example, the laminated composite material of this embodiment may be molded into a large cloth-like molded product (fabric) and then appropriately cut, sewn, or otherwise processed to form the final product shape, or the product shape may be obtained by stacking sheets that have been cut to the product shape in advance and molding them by thermocompression.
When the laminated composite material of this embodiment is cut, the carbon fiber fabric CF is exposed on the cut surface. If it is not desirable for the carbon fiber fabric CF to be exposed on the cross section, it is desirable to cut and mold each sheet into a product shape before thermocompression bonding. At this time, by cutting the thermoplastic resin sheets PU1 and PU2 (either or both) to a size slightly larger than the cut size of the carbon fiber fabric CF, a thermoplastic resin sheet overlap portion is formed on the outer periphery, and thus it is possible to prevent the carbon fiber fabric CF from being exposed on the outer periphery.

As described above, the belt (laminated composite material) 1 of the present embodiment is a new material that has not been seen before, and can significantly expand the range of uses for designs that result from patterns that appear as a result of weaving carbon fibers.
In addition, in the belt (laminated composite material) 1 of this embodiment, since the thermoplastic resin sheet is formed on the surface of the carbon fiber fabric CF, the texture and feel of the surface can be improved and safety can be improved. Furthermore, painting of the surface is not required, and even when painting the surface, a beautiful painted surface can be easily obtained.
According to this embodiment, the surface of the thermoplastic resin sheet PU1 can be protected and the design of the surface can be improved by using the release sheet RP disposed between the thermoplastic resin sheet PU1 and the mold T. In addition, the use of the release sheet RP can reduce damage to the mold T and extend the life of the mold T.

In this embodiment, the design surface of the product is basically on only one side, so the thermoplastic resin sheet PU2 on the back side is thin and no release sheet is provided during molding, but if both sides have design surfaces, the thermoplastic resin sheet PU2 side may also be configured in the same way as the thermoplastic resin sheet PU1.
FIG. 4 shows a laminated composite material 1' as such an example. The thermoplastic resin sheet PU2' is the same as the thermoplastic resin sheet PU1 in the above embodiment. FIG. 5 is an explanatory diagram showing a manufacturing method of the laminated composite material 1'. As shown in the figure, a first release sheet RP1 (similar to the release sheet RP in the above embodiment) is arranged on the lower surface of the thermoplastic resin sheet PU1, a second release sheet RP2 (similar to the release sheet RP in the above embodiment) is also arranged on the upper surface of the thermoplastic resin sheet PU2', and the thermoplastic resin sheet PU2' is molded by thermocompression bonding in this state, thereby protecting the upper surface side of the thermoplastic resin sheet PU2' and improving the design of the surface.

In this embodiment, the laminated composite material is exemplified by a three-layer structure of a thermoplastic resin sheet PU1, a carbon fiber fabric CF, and a thermoplastic resin sheet PU2, but the present invention is not limited thereto, and any laminated composite material may be used as long as it has at least "a thermoplastic resin sheet heat-pressed onto the upper and lower surfaces of the carbon fiber fabric." For example, the number of layers of the thermoplastic resin sheet and the carbon fiber fabric, or the number of repetitions of the thermoplastic resin sheet and the carbon fiber fabric may be increased or decreased, or the laminated composite material may further include another material layer (for example, a coating film).
Fig. 6 shows a laminated composite material 1'' as an example in which the number of repetitions of thermoplastic resin sheets and woven carbon fiber fabrics is increased. Note that the same reference numerals are used for components having the same configuration as in Figs. 1 and 4.
The laminated composite material 1" has a five-layer structure in which a thermoplastic resin sheet PU1, a carbon fiber fabric CF1, a thermoplastic resin sheet PU3, a carbon fiber fabric CF2, and a thermoplastic resin sheet PU2' are laminated in this order. The carbon fiber fabrics CF1 and CF2 are the same as the carbon fiber fabric CF in the embodiment. The thermoplastic resin sheet PU3 is a polyurethane sheet having a thickness of 100 μm.
Increasing the number of layers in this way makes it possible to obtain a thick laminated composite material. In addition, if there is only one layer of carbon fiber fabric, the gaps between the carbon fibers may be visible (appear as holes when light is passed through them), but by laminating the carbon fiber fabric as shown in FIG. 6, the visibility of the gaps between the carbon fibers is reduced. Based on this viewpoint, an opaque sheet may be used (an opaque layer is formed) for the thermoplastic resin sheet PU3 sandwiched between the carbon fiber fabrics. When an opaque layer is formed, it is preferable to provide it at a location other than between the thermoplastic resin sheet that is the surface of the product and the carbon fiber fabric. This is because providing an opaque layer between the thermoplastic resin sheet that is the surface of the product and the carbon fiber fabric makes it impossible to obtain the design of the weave of the carbon fiber fabric.

In addition, in this embodiment, polyurethane is used as an example of a thermoplastic resin, but the present invention is not limited to this. As the thermoplastic resin sheet used in the laminated composite material, various resins can be used in accordance with the design concept of design, texture, feel, flexibility, safety, etc., and it is preferable that the resin has the function of an elastic material or a flexible material.

In this embodiment, a laminated composite material that is molded in a two-dimensional shape is used as an example, but the present invention is not limited to this, and the laminated composite material may be molded in a three-dimensional shape.
A three-dimensional mold is used as a molding die, and each sheet is laminated on this three-dimensional mold, and then molded by hot compression in an autoclave, whereby a laminated composite material can be molded three-dimensionally.

In this embodiment, the thermocompression bonding of the carbon fiber fabric and the thermoplastic resin sheet is performed by autoclave molding, but this is not limited to this and may be performed by, for example, heat pressing or ultrasonic melting.

<Embodiment 2>
In the embodiment 2, a coating layer is provided on the surface of the laminated composite material described in the embodiment 1. More specifically, the fine irregularities on the surface of the release sheet RP are transferred to the surface of the thermoplastic resin layer having a fine irregularity, and a coating layer having a thickness thinner than the surface roughness Rz of the release sheet RP is provided on the surface of the thermoplastic resin layer.

FIG. 7 is a diagram for explaining the coating layer of the laminated composite material of this embodiment.
7(a) is a schematic diagram showing the unevenness of the surface of the laminated composite material described in embodiment 1. As shown in the figure, the surface S of the laminated composite material described in embodiment 1 has unevenness due to the transfer of the unevenness of the surface of the release sheet RP, which causes light to be diffusely reflected and gives a matte feel. Rz in the figure indicates the maximum height as surface roughness. The surface roughness Rz is the sum of the highest and deepest parts of a part of the roughness curve measured by a roughness meter, extracted at a reference length. The unevenness of the surface S of the laminated composite material is the unevenness of the surface of the release sheet RP transferred, and the surface roughness Rz of the surface S of the laminated composite material is formed to be equal to or less than the surface roughness Rz of the release sheet RP.

The unevenness of the surface S gives it a matte feel, but the unevenness of the surface also means that stains such as fingerprints tend to adhere easily and are difficult to remove.
The laminated composite material of the present embodiment has a coating layer on the surface, which makes stains such as fingerprints less noticeable and easier to remove, while also preventing the matte finish from being lost.

FIG. 7(b) is a conceptual diagram showing a coating layer Cl on the surface of the laminated composite material of this embodiment.
The coating layer Cl is formed of a fluororesin (for example, "Kapron GS-5" by Nissin Scientific Research Institute Co., Ltd.) which is an antistatic agent and a water repellent agent, and has light transmissivity. The coating layer Cl is formed by spraying a diluted fluororesin liquid onto the surface of the laminated composite material described in the first embodiment, wiping off the excess with a rag, and then drying the material.
By wiping off the fluororesin liquid before drying with a cloth or other rag having fine irregularities on its surface, the fluororesin liquid is wiped off so as to penetrate into the irregularities of the surface S of the laminated composite material. As a result, a coating layer Cl having a thickness thinner than the surface roughness Rz of the surface S of the laminated composite material is formed, as shown in Fig. 7(b) .

FIG. 7C shows a case where a coating layer Cl' is formed having a thickness Th that is thicker than the surface roughness Rz of the surface S of the laminated composite material.
In Fig. 7C, the surface is smoothed by the coating layer Cl', which is effective in preventing adhesion of dirt and making it easier to remove dirt, but the matte feel of the surface is lost.

In contrast, according to this embodiment, by having a coating layer Cl having a thickness thinner than the surface roughness Rz of the surface S, it is possible to make stains such as fingerprints less noticeable and easier to remove, while also preventing the matte finish from being lost. In order to obtain a more distinct matte finish, it is preferable that the surface roughness Ra of the coating layer Cl after it is formed is 0.5 μm to 1.0 μm, and therefore a release sheet having a surface roughness Ra greater than that of embodiment 1 (0.5 μm to 1.0 μm) may be used.
In addition, in this embodiment, the coating layer Cl is formed using fluororesin, which is an antistatic agent and a water repellent agent, so that adhesion of dirt due to static electricity can be reduced, and the effect of preventing adhesion of dirt and making it easier to remove dirt can be further enhanced.

In this embodiment, the maximum height Rz is used for the surface roughness of the surface S, but the arithmetic mean roughness Ra may be used to form a "coating layer Cl having a thickness thinner than the surface roughness Ra of the surface S." As described above, the arithmetic mean roughness Ra is obtained by extracting a portion of the roughness curve measured by a roughness meter over a reference length and expressing the unevenness of that section as an average value. With respect to the surface roughness Ra of the surface S, a portion of the curve showing the difference between the curve representing the surface of the surface S and the curve representing the surface of the coating layer Cl is extracted over a reference length, and the unevenness of that section expressed as an average value is made smaller.
In addition, in the present embodiment, the coating layer is formed from a fluororesin, but the present invention is not limited to this. For example, a silicone-based coating agent may be used.

<Embodiment 3>
In the third embodiment, a foamed ABS resin layer is included in the laminate structure of the laminated composite material described in the first embodiment.
FIG. 8 is a schematic diagram showing the layered structure of the laminated composite material of this embodiment.
8, the laminated composite material 2 of this embodiment is constructed by laminating a thermoplastic resin sheet PU21, a carbon fiber fabric CF21, a thermoplastic resin sheet PU22, a foamed ABS resin board ABSr, a thermoplastic resin sheet PU23, the carbon fiber fabric CF22, and a thermoplastic resin sheet PU24, and then thermocompression bonding them together. Note that release sheets RP are provided on the lower surface side of the thermoplastic resin sheet PU21 and the upper surface side of the thermoplastic resin sheet PU24, respectively, and are thermocompression bonded (the release sheet RP is peeled off after thermocompression bonding).
As a result, the laminated composite material of this embodiment has a seven-layer structure including a first thermoplastic resin layer (a polyurethane layer in this embodiment), a first carbon fiber fabric layer, a second thermoplastic resin layer (a polyurethane layer in this embodiment), a foamed ABS resin layer, a third thermoplastic resin layer (a polyurethane layer in this embodiment), a second carbon fiber fabric layer, and a fourth thermoplastic resin layer (a polyurethane layer in this embodiment).

The foamed ABS resin board ABSr is a synthetic resin foam plate made of acrylonitrile butadiene styrene, and in this embodiment, one with an expansion ratio of 1.5 to 2.5 and a thickness of 3 mm to 5 mm is used. An expansion ratio of 2 times means that the volume becomes twice that of the unfoamed case due to foaming.
The foamed ABS resin board ABSr is lightweight and has high impact resistance.
The release sheet RP, the thermoplastic resin sheets, and the carbon fiber fabric are the same as those in the first embodiment, and therefore the description thereof will be omitted here.

The laminated composite material of this embodiment has a foamed ABS resin layer that is inexpensive, lightweight, and highly impact resistant, making it possible to obtain a laminated composite material with high strength at low cost.

The laminated composite material of the present embodiment is formed by laminating a thermoplastic resin sheet onto a foamed ABS resin board and then thermocompression bonding the resultant in an autoclave. As a result, the layers have high adhesion to each other and peeling between the layers is unlikely to occur.
Since the foamed ABS resin board is a foamed material, it has fine irregularities on its surface, and the thermoplastic resin of the thermoplastic resin sheet penetrates into the irregularities and hardens, resulting in high adhesion. In addition, since the bag containing the laminated composite material is evacuated in the autoclave, it is possible to prevent a decrease in adhesion caused by air remaining between the layers, thereby obtaining a higher adhesion.

The formation of the laminated composite material in this embodiment is a simple process of stacking the sheets described in embodiment 1, with foamed ABS resin boards being stacked where necessary, reducing not only material costs but also labor costs.

In this embodiment, the seven-layer structure described above is taken as an example, but the present invention is not limited to this. For example, the number of repetitions of the thermoplastic resin layer and the carbon fiber fabric may be increased or decreased, or other material layers (for example, carbon fiber reinforced plastic layers or paint films) may be provided.
For example, a four-layer structure of a first thermoplastic resin layer, a first carbon fiber fabric layer, a second thermoplastic resin layer, and a foamed ABS resin layer may be used. However, as in this embodiment, it is more preferable that the number of laminations of carbon prepregs on the upper surface side and the lower surface side of the foamed ABS resin layer is the same. It is also preferable that the number of laminations of thermoplastic resin sheets and carbon prepregs on the upper surface side and the lower surface side of the foamed ABS resin layer is the same. It is also more preferable that the layer structure is symmetrical with the foamed ABS resin board at the center.

<Embodiment 4>
The fourth embodiment is a laminated composite material in which a carbon fiber reinforced plastic layer is thermocompression bonded to a foamed ABS resin layer.
FIG. 9 is a schematic diagram showing the layered structure of the laminated composite material of this embodiment.
As shown in FIG. 9, the laminated composite material 3 of this embodiment has carbon fiber reinforced plastic layers CFP formed on both sides of a foamed ABS resin board ABSr.
The laminated composite material 3 is obtained by laminating 200 μm thick carbon prepregs on both sides of an ABS resin board ABSr, laminating a release sheet on the carbon prepregs, and thermocompressing the laminate together (the release sheet RP is peeled off after thermocompression bonding). The foamed ABS resin board ABSr is the same as that in the third embodiment, and the release sheet is the same as that in the first embodiment.

The laminated composite material of this embodiment is formed by laminating carbon prepreg onto a foamed ABS resin board and then thermocompression bonding using an autoclave or the like, so that the layers have high adhesion and are less likely to peel off from each other.
Since the foamed ABS resin board is a foamed material, it has fine irregularities on its surface, and the matrix resin of the carbon prepreg penetrates into the irregularities and hardens, resulting in high adhesion. In addition, by using an autoclave, the bag containing the laminated composite material is evacuated, which prevents a decrease in adhesion caused by air remaining between the layers, and thus allows for higher adhesion to be obtained.

The foamed ABS resin board ABSr is lightweight and highly impact resistant, and is formed by completely adhering it to carbon fiber reinforced plastic, a material with a very small elasticity rate, making it possible to create a material with high bending rigidity, light weight, and high impact resistance.
Carbon fiber reinforced plastics are lightweight and strong, but in order to obtain high strength, it is necessary to increase the number of carbon prepreg layers. However, using a large number of carbon prepregs increases costs. In contrast, the above laminated composite material can provide a laminated composite material that is low cost, has high strength, and can be used for many purposes.

In this embodiment, the foamed ABS resin layer has carbon fiber reinforced plastic layers formed on both sides thereof, but the foamed ABS resin layer may have a carbon fiber reinforced plastic layer formed on only one side thereof, or multiple carbon fiber reinforced plastic layers may be formed on one or both sides thereof. However, it is preferable to provide carbon fiber reinforced plastic layers on both sides of the foamed ABS resin board, and it is preferable to have the same number of carbon fiber reinforced plastic layers on both sides. By providing carbon fiber reinforced plastic layers on both sides of the foamed ABS resin board, higher rigidity can be obtained, and the symmetrical layer structure with the foamed ABS resin board at the center can reduce warping of the laminated composite material.
When the product is used in an environment exposed to ultraviolet rays, it is preferable to form a surface layer having weather resistance on the carbon fiber reinforced plastic layer exposed to ultraviolet rays, for example, a thermoplastic resin layer such as polyurethane may be formed on the surface of the carbon fiber reinforced plastic layer that serves as the surface. The thermoplastic resin layer may be formed as a coating film, for example.
Also, for the purpose of imparting flexibility to the material, an elastomeric layer may be provided between the carbon fiber reinforced plastic layer. The elastomeric layer promotes relative sliding between the foamed ABS resin layer and the carbon fiber reinforced plastic layer, and this phenomenon results in the flexibility of the laminated composite material.

10 shows an example in which a thermoplastic resin layer PU1 is formed on the surface of the upper carbon fiber reinforced plastic layer, and the lower carbon fiber reinforced plastic layer is formed into two layers, with an elastomeric layer (thermoplastic resin layer PU2) provided between the carbon fiber reinforced plastic layers. The thermoplastic resin layers PU1 and PU2 are formed by the thermoplastic resin sheets PU1 and PU2 described in the first embodiment, the carbon fiber reinforced plastic layers CFP are formed by the carbon prepregs described in the fourth embodiment, and the foamed ABS resin board ABSr is formed by the foamed ABS resin board described in the third embodiment, and are formed by laminating the release sheet RP, the thermoplastic resin sheet PU1, the first carbon prepreg CFP, the foamed ABS resin board ABSr, the second carbon prepreg CFP, the thermoplastic resin sheet PU2, and the third carbon prepreg CFP, and then thermocompressing them together (the release sheet RP is peeled off after thermocompression bonding).
In a bag as described in the first embodiment, if the laminated composite material of Fig. 10 is used in the bottom portion, the bottom of the bag can be reinforced at low cost. In particular, in the case of a bag with casters, the bottom portion where the casters are located has a beam structure, so it is effective to reinforce it with the laminated composite material of Fig. 10. Of course, the laminated composite material of Fig. 10 may be used in places other than the bottom portion.

The foamed ABS resin in the third and fourth embodiments may be formed into a molded article (ABS resin molded article) having a three-dimensional structure, not just a flat plate.
The foamed ABS resin can be formed into a molded article having a three-dimensional structure (ABS resin molded article), which can be used as a preform for forming a laminated composite material.
For example, an ABS resin molded product having a three-dimensional structure is formed from foamed ABS resin, and then a release sheet and a laminated sheet having a carbon prepreg with a thermoplastic resin sheet laminated on at least one surface of the mold are laminated on the mold so that the release sheet and the thermoplastic resin sheet are in contact with each other, thereby forming a laminated structure as explained in FIG. 8, and the laminated structure is integrally fitted into a mold and thermocompression bonded to form the laminated composite material of this embodiment.
As is clear from this explanation, the ABS resin molded product can be made to function as a preform mold (a tool for improving the efficiency and precision of the work of laminating carbon prepregs and thermoplastic resin sheets in a molded state).

1. Belt (Laminated Composite Material)
CF... Carbon fiber fabric PU1, PU2... Thermoplastic resin sheet RP... Release sheet T... Mold 100... Bag Cl... Coating layer ABSr... Foamed ABS resin layer CFP... Carbon fiber reinforced plastic layer

Claims (8)

A carbon fiber fabric woven from carbon fibers;
and a thermoplastic resin layer having an elastomeric property, the thermoplastic resin layer being heat-compressed to the upper surface and the lower surface of the carbon fiber fabric,
The surface roughness Ra of the thermoplastic resin layer is 0.5 μm to 1.0 μm,
a coating layer having a thickness smaller than the surface roughness Ra of the thermoplastic resin layer on a surface of the thermoplastic resin layer ;
A laminated composite material, characterized in that the thermoplastic resin of the elastomeric thermoplastic resin layer is polyurethane . The laminated composite material according to claim 1, characterized in that the coating layer is formed from an antistatic agent or a water repellent agent. The laminated composite material according to claim 1 or 2, characterized in that the coating layer is formed from a fluororesin. A foamed ABS resin layer and a carbon fiber reinforced plastic layer,
a thermoplastic resin layer having an elastomeric property that is provided between the foamed ABS resin layer and the carbon fiber reinforced plastic layer and that promotes relative sliding between the foamed ABS resin layer and the carbon fiber reinforced plastic layer;
having
A laminated composite material, characterized in that the thermoplastic resin of the elastomeric thermoplastic resin layer is polyurethane . The laminated composite material according to claim 4, characterized in that the carbon fiber reinforced plastic layers are formed on both sides of the foamed ABS resin layer via the thermoplastic resin layers having elastomeric properties. The laminated composite material according to claim 5, characterized in that the number of layers of the carbon fiber reinforced plastic layer on the upper surface side and the lower surface side of the foamed ABS resin layer is the same. A foamed ABS resin layer;
a polyurethane layer which is a thermoplastic resin layer provided on the foamed ABS resin layer;
a carbon fiber fabric woven from carbon fibers provided on the polyurethane layer;
a polyurethane layer provided on the carbon fiber fabric;
A laminated composite material comprising : 8. The composite laminate according to claim 7, wherein the number of layers of the thermoplastic resin layer and the carbon fiber fabric on the upper surface side and the lower surface side of the foamed ABS resin layer is the same.

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