KR20200076232A - Sheet - Google Patents

Abstract

The present application relates to a sheet, a method for manufacturing the same and its use. According to the present application, high strength and light weight can be realized, and such a seat can be applied to a side skirt for a trailer to reduce fuel consumption.

Description

Sheet {SHEET}

The present application relates to a sheet, a method for manufacturing the same and its use.

Sheets produced by impregnating continuous fibers with a matrix resin can utilize the mechanical properties of the fibers according to the arrangement direction of the fibers.

In general, a sheet including a prepreg formed by impregnating a resin into a fiber sheet having a single direction is manufactured, or a sheet is manufactured by laminating a plurality of prepregs.

Since the sheet manufactured as described above has excellent torsion resistance and bending resistance, it is widely used in various fields such as structures for sports and leisure such as golf clubs and structures such as telephone poles.

However, automobile parts, ships, and aircraft that require high strength such as side skirts, seat backs, and bumper back beams for automobiles have a high fuel efficiency due to increased weight to improve strength. A problem occurred.

Therefore, there is a need for a sheet for solving this problem.

An object of the present application is to provide a high-strength and lightweight sheet, a method for manufacturing the same, and uses thereof.

This application relates to sheets. Hereinafter, a sheet of the present application will be described with reference to the accompanying drawings, and the attached drawings are exemplary and the sheet of the present application is not limited to the attached drawings.

1 shows a sheet according to an embodiment of the present application. As shown in Fig. 1, a core layer (A) containing a self-reinforcing resin and skin layers (B10, B20) located on opposite sides of the core layer are included.

The core layer (A) has a reinforcing material (a1) and a matrix (a2) having different melting points. In the present specification, the reinforcing material (a1) means a fibrous material oriented in a single direction to increase the strength of the sheet. In addition, in the present specification, the base material (a2) means a material surrounding the reinforcing material (a1) and imparting adhesive force to the reinforcing material (a1).

The core layer (A) containing the self-reinforcing resin means a core layer in which the reinforcing material (a1) and the base material (a2) are made of the same component. For example, the component may be a resin or a polymer. The reinforcing material (a1) and the base material (a2) are made of the same component, and thus can provide excellent interfacial adhesion, thereby providing a sheet having excellent strength.

The same components used for the reinforcing material (a1) and the base material (a2) are not particularly limited. In one example, the reinforcing material (a1) and the base material (a2) may include an olefin-based resin. Specifically, the reinforcing material (a1) and the base material (a2) may include propylene resin.

The melting points of the reinforcing material (a1) and the base material (a2) may be different. Specifically, the melting point of the matrix (a2) may be lower than the melting point of the reinforcement (a1). Since the base material (a2) has a lower melting point than the reinforcing material (a1), it can be melted earlier than the reinforcing material (a1) in the bonding step described later, and can have the reinforcing material (a1) fixed.

In one example, the melting point of the matrix (a2) may be 120 ℃ to 160 ℃. Specifically, the melting point of the base material (a2) may be 125°C to 155°C, 130°C to 150°C, or 135°C to 145°C.

In addition, the melting point of the reinforcing material (a1) is not particularly limited as long as it is higher than the melting point of the base material (a2). For example, the melting point of the reinforcing material (a1) may be a lower limit of 160°C or higher, 165°C or higher, or 170°C or higher, and an upper limit of 200°C or lower, 190°C or lower, or 180°C or lower. The core layer (A), by including a reinforcing material (a1) having a melting point in the above-described range, does not melt during sheet production, it is possible to maintain the shape.

In one example, the core layer (A) may include the reinforcing material (a1) in excess of the base material (a2). Specifically, the core layer (A) may include 50% to 80% by weight of the reinforcing material (a1), and 20% to 50% by weight of the matrix (a2). More specifically, the content of the reinforcing material (a1) included in the core layer (A) may be 60% to 70% by weight. In addition, the content of the matrix (a2) contained in the core layer (A) may be 30% to 40% by weight. The core layer (A) may exhibit excellent strength by including the reinforcing material (a1) and the base material (a2) in a content within the aforementioned range.

2 is a view showing to explain a method of manufacturing a core layer (A) containing a self-reinforcing resin according to an embodiment of the present application. As shown in FIG. 2, the reinforcing material (a1) and the reinforcing material (a2') are melted at a temperature equal to or higher than the respective melting points and then simultaneously extruded, whereby the reinforcing material (a2') is melted by the coextrusion method. It can be formed to surround the outside of a1). Thereafter, after stretching the base material (a2') surrounding the outside of the reinforcement material (a1) in a molten state, as shown in FIG. 3A, the fiber surrounding the base material (a2') outside the reinforcement material (a1) It can take the form. In the present specification, the "base material (a2')" means a material corresponding to the precursor of the base material (a2), and specifically, the base material (a2) of the core layer (A) is formed in the laminating step described later. It may be a material that previously surrounds the reinforcement (a1).

In one example, two or more of the reinforcing material (a1) surrounding the outside of the base material (a2') after weaving using a weaving machine commercially available in the art, the two or more of the reinforcing material (a1) surrounding the outer material ( By laminating the skin layers B10 and B20 on both sides of a2'), the core layer A in the form of a woven fabric can be formed, as shown in Fig. 3B.

In another example, two or more base materials (a2') surrounding the outside of the reinforcement (a1) are not woven, and two or more base materials (a2') surrounding the outside of the reinforcement (a1) are aligned in the same direction. After the lamination, by laminating the skin layers B10 and B20 on both sides to face each other, as shown in FIG. 3C, the core layer A having a base material a2 surrounding the outside of the reinforcing material a1 is formed in one direction. ).

For example, the woven fabric may include plain weave, twill weave or satin weave. The plain weave refers to an organization in which weft and warp yarns appear one after another. In addition, the twill means a tissue in which weft or warp yarns cross over two or more yarns to cross to make a pattern appear in an oblique direction. In addition, vertical textile refers to a tissue in which warp or weft appears on the fabric surface. The core layer can exhibit excellent impact resistance of the sheet by exhibiting the woven form described above.

The skin layers B10 and B20 have glass fiber reinforcement materials b11 and b21 and base materials b12 and b22.

In one example, the glass fiber reinforcement (b11, b21) may be a continuous glass fiber. The continuous glass fiber means a glass fiber that is continuous without being physically cut. For example, the continuous glass fibers may be divided into individual unit skeletons according to physical continuity or intermittence. The glass fiber reinforcement (b11, b21) extends from the first edge of the skin layer (B10, B20) impregnated with the glass fiber reinforcement (b11, b21) in a state of physical continuity to face the first edge It can be in contact with the second edge. By using the glass fiber reinforcement (b11, b21) in the form of continuous glass fibers, it is possible to form and maintain the orientation better than when using non-continuous fibers cut to have a predetermined length, such as short fibers.

And, one skin layer (B10, B20) may include two or more glass fiber reinforcement (b11, b21). In addition, the two or more glass fiber reinforcements (b11, b21) included in one layer may be aligned in the skin layers (B10, B20). The glass fiber reinforcing materials (b11, b21) may be, for example, a kind of fiber skeleton formed by stacking or twisting single stranded fibers such as glass fibers. The base material (b12, b22) includes an olefin-based resin, and the melting point of the base material (b12, b22) may be 120°C to 150°C. Specifically, the melting point of the matrix (b12, b22) may be 125 ℃ to 148 ℃, 130 ℃ to 145 ℃ or 135 ℃ to 143 ℃. The base materials (b12, b22) may include the olefin-based resin having a melting point in the above-described range, thereby achieving the same component having the same melting point as the base material (a2) of the core layer (A). When manufacturing the sheet, the adhesive strength at the interface between the core layer (A) and the skin layers (B10, B20) may be excellent.

Accordingly, the matrix (a1) and the matrix (b12, b22) may be fused to each other. Since the base material (a1) and the base materials (b12, b22) are fused to each other, the adhesive force at the interface between the core layer (A) and the skin layers (B10, B20) without using a separate adhesive is present. Can be excellent

The skin layers B10 and B20 include a first skin layer B1 and a second skin layer B2 having different alignment directions of the glass fiber reinforcement materials.

In one example, the stacking order of the skin layers B10 and B20 is not particularly limited. For example, the first skin layer B1 is formed to be adjacent to the core layer A compared to the second skin layer B2, or the second skin layer B2 is the first skin layer B1. ) May be formed to be adjacent to the core layer (A).

In one example, the first skin layer (B1) comprises a glass fiber reinforcement (b11, b21) aligned in the first direction, the second skin layer (B2) is a glass fiber reinforcement aligned in the second direction (b12, b22).

Specifically, the alignment direction is different from each other, the glass fiber reinforcement of each of the first skin layer (B1) and the second skin layer (B2) may be arranged in a single direction, and the glass of the first skin layer (B1) It may mean that the alignment directions of the fiber reinforcement and the glass fiber reinforcement of the second skin layer B2 cross each other.

The alignment direction of the glass fiber reinforcement (b11) of the first skin layer (B1) and the glass fiber reinforcement (b21) of the second skin layer (B2) is not particularly limited. In one example, the first direction and the second direction may be orthogonal. In the present specification, "orthogonal" means that the angle between the first direction and the second direction is 90 degrees, but substantially, an angle that allows an error of ± 10, ± 5, ± 3, ± 1, or ± 0.1 Can mean Since the alignment directions of the glass fiber reinforcements b11 and b21 included in each of the first skin layer B1 and the second skin layer B2 are orthogonal to each other, it may be advantageous to secure resistance to external forces on the side surfaces.

In addition, the first skin layer (B1) and the second skin layer (B2) may be composed of one to two layers, respectively. The skin layers (B10, B20) including the first skin layer (B1) and the second skin layer (B2) made of the above-described number of layers are respectively 2 to 4 layers on opposite sides of the core layer (A). Can be formed. Even if the skin layers (B10, B20) including the first skin layer (B1) and the second skin layer (B2) composed of the above-described number of layers are included in the above-described number of layers, the sheet is made lighter by satisfying the low density described later. I can do it.

In one example, the skin layer (B10, B20) comprises the glass fiber reinforcement (b11, b21) 40% by weight to 70% by weight, the base material (b12, b22) 30% by weight to 60% by weight %. Specifically, the skin layers (B10, B20) may include the glass fiber reinforcement (b11, b21) in excess of the base material (b12, b22). More specifically, the content of the glass fiber reinforcement (b11, b21) may be a lower limit of 50% by weight or more or 55% by weight or more, and an upper limit of 65% by weight or less. In addition, the content of the matrix material (b12, b22) included in the skin layers (B10, B20) may be 35% by weight or more, and the upper limit may be less than 50% by weight or 45% by weight or less. The skin layers (B10, B20) may include the glass fiber reinforcement (b11, b21) and the base materials (b12, b22) with a content within the above-described range, thereby realizing high strength and light weight.

In one example, the density of the sheet may be 0.5 g/cm ³ to 1.5 g/cm ³ , specifically, 0.6 g/cm ³ to 1.4 g/cm ³ , 0.7 g/cm ³ to 1.3 g/cm ³ , 0.8 g/cm ³ to 1.2 g/cm ³ or 0.9 g/cm ³ to 1.1 g/cm ³ . The sheet may be made lighter by having the above-described density.

The present application also relates to a method for manufacturing a sheet. The method of manufacturing the sheet relates to a method of manufacturing the above-mentioned sheet, and specific details of the sheet to be described later may be the same as described in the sheet.

Exemplary method of manufacturing a sheet of the present application is a glass fiber reinforcement (b11, b21) on both sides of the core layer (A) containing a self-reinforcing resin comprising a reinforcing material (a1) and a base material (a2') having different melting points and And facing and laminating the skin layers B10 and B20 having the base materials b12 and b22.

The self-reinforcing resin-containing core layer (A) may be used by coextruding a reinforcing material (a1) and a base material (a2') having different melting points, and preparing a product stretched in one direction. As the core layer (A) containing a self-reinforcing resin according to an embodiment, a self-reinforcing polypropylene resin (Curv, Propex Fabrics, Germany) may be used.

Specifically, as shown in FIG. 2, the coextrusion melts the reinforcing material (a1) and the matrix (a2') at a temperature equal to or higher than each melting point, and simultaneously extrudes the matrix (a2') in a molten state. It may be formed to surround the outer side of the reinforcing material (a1). Thereafter, after stretching the base material (a2') surrounding the outer side of the reinforcing material (a1) in a molten state, as shown in FIG. 3A, to form a base material (a2') surrounding the outer axis of the reinforcing material (a1). Can.

Subsequently, in one example, two or more base materials surrounding the outside of the reinforcing material (a1) (a2') are woven using a weaving machine commercially available in the art, and then two or more bases surrounding the outside of the reinforcing material (a1) The skin layers (B10, B20) are laminated on both surfaces of the ash (a2') to face each other, so that a core layer (A) containing a self-reinforcing resin in the form of a woven fabric shown in Fig. 3B can be produced.

In another example, after aligning two or more of the matrix (a2') surrounding the outer axis of the reinforcement (a1) in the same direction, the two or more of the matrix (a2') surrounding the outer axis of the reinforcement (a1) By laminating the skin layers (B10, B20) on both sides, a core layer (A) containing a self-reinforcing resin in a form in which a base material (a2) surrounding the outside of the reinforcing material (a1) shown in FIG. 3C is formed in one direction can be manufactured. have.

At this time, by coextruding the reinforcing material (a1) and the base material (a2'), the base material (a2') surrounds the outer axis of the reinforcing material (a1), and the base surrounding the outer axis of the two or more reinforcing materials (a1) The temperatures of the base materials (a2') and the base materials (b2') included in the skin layers (B10, B20) when laminating the skin layers (B10, B20) on both sides of the ash (a2'). Since it melts in, it is possible to produce a sheet of sandwich structure.

The manufacturing method of the sheet may further include forming skin layers B10 and B20. 4 is a view illustrating a step of forming a skin layer according to an embodiment of the present application. As shown in FIG. 4, the step of forming the skin layer may be performed by impregnating the base materials b12 and b22 inside the glass fiber reinforcement materials b11 and b21.

Specifically, the glass fiber reinforcing materials (b11, b21) are wound from a krill device wound thereon, and the glass fiber reinforcing materials (b11, b21) having a diameter of 15 μm to 20 μm are aggregated by 3,500 to 4,500 strands by a bundling agent 1 One roll having a width of mm to 5 mm can be formed (see reference numeral 41 in FIG. 4). Thereafter, the glass fiber reinforcement (b11, b21) may be spread to 5 mm to 15 mm per roll through a spreading roll (see reference numeral 42 in FIG. 4). Then, by supplying the base materials (b12, b22) to the impregnating die, the glass fiber reinforcement (b11, b21) is within the temperature of 200°C to 240°C and the melt viscosity of the base materials (b12, b22). It can be impregnated with ashes b12 and b22 (see reference numeral 43 in FIG. 4). In this way, the step of forming the skin layer may be performed. In step 43 of FIG. 4, the glass fiber reinforcements (b11, b21) that have undergone the spreading roll may be specifically, 7 mm to 13 mm or 9 mm to 11 mm per roll. By spreading the glass fiber reinforcing materials (b11, b21) through the spreading roll in the above-described range, it may be easy for the base materials (b12, b22) to be impregnated between the glass fiber reinforcing materials (b11, b21). In addition, the temperature at the time of impregnation may be 210°C to 230°C or 220°C to 230°C. When the temperature during the impregnation satisfies the above-described range, the fluidity of the base materials (b12, b22) is high and the viscosity is low, so that the base materials (b12, b22) are impregnated between the glass fiber reinforcement materials (b11, b21). It can be easy.

In one example, forming the skin layers B10 and B20 may further include calendering and cutting. Specifically, the calendering may be performed by pressing and cooling the base materials (b12, b22) impregnated in the glass fiber reinforcement (b11, b21) through the calender (see reference numeral 44 in FIG. 4). The cutting may be performed by cutting the skin layers B10 and B20 that have undergone the calendering to a size according to the intended use (refer to reference numeral 45 in FIG. 4 ).

5 is a view illustrating a laminating step according to an embodiment of the present application. As shown in Fig. 5, the laminating step involves laminating skin layers (B10, B20) having glass fiber reinforcement (b11, b21) and matrix (b12, b22) on both sides of the core layer (A). Perform. Specifically, the lamination may be performed using a heat press, and in one embodiment, may be performed using a double belt press or the like.

In one example, the laminating step may be performed at 140°C to 160°C, considering the melting points of the core layer (A) and the skin layers (B10, B20), and specifically, 143°C to 158 ℃, 145 ℃ to 155 ℃ or may be carried out at 148 ℃ to 152 ℃. By performing the laminating step in the above-described temperature range, the core layer (A) and the skin layers (B10, B20) can be laminated with excellent adhesion.

The present application also relates to the use of the sheet. The sheet of the present application can exhibit high strength and light weight. Such a seat can be applied, for example, to a side skirt for a trailer.

The seat of the present application can implement high strength and light weight, and such a seat can be applied to a side skirt for a trailer to reduce fuel consumption.

1 shows a sheet according to an embodiment of the present application.
2 is a view illustrating a step of forming a core layer according to an embodiment of the present application.
Figure 3a is a view showing a base material (a2') surrounding the outer axis of the reinforcement (a1) formed after co-extrusion according to an embodiment of the present application.
3B shows a core layer (A) in the form of a woven fabric according to an embodiment of the present application.
Figure 3c shows a cross-section of the core layer (A) in the form of a base material (a2) surrounding the outer axis of the reinforcing material (a1) in one direction according to another embodiment of the present application.
4 is a view illustrating a step of forming a skin layer according to an embodiment of the present application.
5 is a view illustrating a laminating step according to an embodiment of the present application.
6 is a view showing a sheet prepared in Comparative Example 1.
7 is a view showing a sheet prepared in Comparative Example 2.
8 is a view showing a sheet prepared in Comparative Example 3.

Hereinafter, the present application will be described in detail through examples, but the scope of the present application is not limited by the following examples.

Example 1

Sheet production

Sheets were prepared by laminating opposing skin layers (B10, B20) on both sides of the core layer (A) containing the self-reinforcing resin.

Specifically, as the core layer (A) containing the self-reinforcing resin, a reinforcing material (a1) having a melting point of 170° C., a reinforcing material (a1) made of polypropylene resin, and a melting point of 130° C., and a matrix material (a2) made of polypropylene resin. A self-reinforcing polypropylene resin (Curv, Propex Fabrics, Germany) was prepared.

Then, as shown in Figure 4, the glass fiber reinforcement (b1, SE4849, OCV) was wound from the krill equipment (LG House), the glass fiber reinforcement (b11, b21) was released (41). Thereafter, the glass fiber reinforcement (b11, b21) was spread to 10 mm per roll through a spreading roll (LG House) (42). Subsequently, the glass fiber reinforcement (b11, b21) that had been subjected to the spreading roll was moved to an impregnating die (LH House). Thereafter, as the base materials (b12, b22), a polypropylene resin having a melting point of 130° C. was prepared, and then supplied to the impregnating die, the glass fiber reinforcement materials (b11, b21) were placed at the temperature of 150° C. Ash (b12, b22) was impregnated (43). Thereafter, the reinforcing material (b11, b21) impregnated in the base material (b12, b22) is compressed through a calender having a spacing of 0.3 mm between the upper roll and the lower roll, and the temperature of the upper roll and the lower roll is 60°C. And after cooling (44), by cutting into a width of 8000 mm and a length of 1000 mm (45), a thickness of 0.25 mm, the first skin layer (B1) in which the glass fiber reinforcement (b11, b21) faces in the first direction, and A second skin layer (B2) in which the glass fiber reinforcement (b11, b21) faces in the second direction was prepared, respectively.

Thereafter, as shown in FIG. 5, the skin layers B10 and B20 on which the first skin layer B1 and the second skin layer B2 are stacked are on both sides of the core layer A containing the self-reinforcing resin prepared above. After being placed so as to face each, at a temperature of 150 °C by laminating with a double belt press (LG House), a 3.5 mm thick sheet was prepared.

Comparative Example 1

Sheet production

As shown in FIG. 6, the core layer was not formed, and the first skin layer and the second skin layer were alternately stacked, and the total number of layers of the first skin layer and the second skin layer was 11 layers. A sheet having a width of 8000 mm, a height of 1000 mm, and a thickness of 3.5 mm was prepared in the same manner as in Example 1.

Comparative Example 2

Sheet production

As shown in FIG. 7, a core layer made of glass fiber reinforcement materials (SE4849, OCV) is prepared, and the first skin layer and the second skin layer are alternately stacked to obtain the total number of layers of the first skin layer and the second skin layer. A sheet having a width of 8000 mm, a height of 1000 mm, and a thickness of 3.5 mm was prepared in the same manner as in Example 1, except that it was formed in three layers.

Comparative Example 3

Sheet production

As shown in FIG. 8, a core layer made of a glass fiber reinforcement material (SE4849, OCV) is prepared, and the reinforcing materials impregnated in the base material included in each of the first skin layer and the second skin layer are woven into a plain weave to form a skin layer. A sheet having a width of 8000 mm, a height of 1000 mm, and a thickness of 3.5 mm was prepared in the same manner as in Example 1, except that it was prepared.

Experimental example. Property evaluation

Using an underwater hydrometer (XP504V, Mettle Toledo), the density and weight of the sheets prepared in Examples and Comparative Examples were measured by ASTM D792, respectively, and the results are shown in Table 1 below.

Density (g/cm ³ ) Weight (kg) Example 1 1.05 29.4 Comparative Example 1 1.41 39.5 Comparative Example 2 1.24 34.7 Comparative Example 3 1.53 42.8

As shown in Table 1, it was confirmed that the sheets prepared in Example 1 had a lower density and weight than the sheets prepared in Comparative Examples 1 to 3 having the same volume.

A: Core layer
a1: reinforcement
a2, a2': base material
B10, B20: Skin layer
B1: first skin layer
B2: second skin layer
b11, b21: glass fiber reinforcement
b12, b22: base material
41: In the method of manufacturing a sheet according to an embodiment of the present application, the process of unwinding the glass fiber reinforcement from krill
42: In the method of manufacturing a sheet according to an embodiment of the present application, the process of spreading a glass fiber reinforcement through a spreading roll
43: In the method of manufacturing a sheet according to an embodiment of the present application, the process of impregnating the glass fiber reinforcement and the base material
44: In the method of manufacturing a sheet according to an embodiment of the present application, the process of calendaring the base material impregnated inside the glass fiber reinforcement
45: In the manufacturing method of the sheet according to an embodiment of the present application, the process of cutting the skin layer

Claims (12)

A core layer (A) containing a self-reinforcing resin having a reinforcing material (a1) and a base material (a2) having different melting points; And
It is formed on opposite sides of the core layer (A), and includes skin layers (B10, B20) having glass fiber reinforcement (b11, b21) and matrix (b12, b22),
The skin layer (B10, B20) is a sheet comprising a first skin layer (B1) and a second skin layer (B2) different from each other in the alignment direction of the glass fiber reinforcement. The sheet according to claim 1, wherein the reinforcing material (a1) and the base material (a2) include an olefin resin, and the melting point of the base material (a2) is lower than the melting point of the reinforcing material (a1). The sheet according to claim 2, wherein the base material (a2) has a melting point within a range of 120°C to 160°C. The sheet according to claim 1, wherein the glass fiber reinforcement (b11, b21) is a continuous glass fiber. The sheet according to claim 3, wherein the matrix (b12, b22) contains an olefin resin, and the melting point of the matrix (b12, b22) is in the range of 120°C to 160°C. The sheet according to claim 5, wherein the base material (a2) and the base material (b21, b22) are fused to each other. According to claim 1, The first skin layer (B1) comprises a glass fiber reinforcement (b11) aligned in the first direction, the second skin layer (B2) is a glass fiber reinforcement (Al) aligned in the second direction ( b21), wherein the first direction and the second direction are orthogonal to each other. The method of claim 1, wherein the skin layer (B10, B20) is 40% by weight to 70% by weight and 30% by weight to 60% by weight of the glass fiber reinforcement (b11, b21) and the matrix (b12, b22), respectively. Sheet containing as. The sheet of claim 1 having a density of 0.5 g/cm ³ to 1.5 g/cm ³ . Skins having glass fiber reinforcement (b11, b21) and matrix (b12, b22) on both sides of the core layer (A) containing a self-reinforcing resin comprising a reinforcing material (a1) and a base material (a2') with different melting points Method of manufacturing a sheet comprising the step of laminating the layers (B10, B20) facing. The method of claim 10, wherein the laminating step is performed at 140°C to 160°C. A side skirt for a trailer comprising the seat of claim 1.

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