JP2018062086A - Heterogeneous laminated composite material and its product - Google Patents

Abstract

[Problem] To be competitive in the market, with a wide selection of materials, structural strength, rigidity and impact resistance can be adjusted by different materials, processing cost is lower than that of a woven resin plate material composed only of a woven layer, and the manufacturing process is simple. To provide a heterogeneous laminated composite material with strength. A heterogeneous laminated composite material includes a first layer structure, a central substrate and a second layer structure in this order, wherein the first layer structure is a woven fiber layer, a metal layer, a resin layer or any of these layers. a combination, wherein the central substrate is a thermoplastic resin plate, the second layer structure comprises a woven fiber layer and a resin layer, or a woven fiber layer and a non-woven fabric, the first layer structure and the second layer structure; The woven fiber layers in A are each connected to the central substrate via an adhesive layer, and the mechanical strength difference between the first layer structure and the second layer structure is 20% or less.

Description

  The present invention relates to one type of composite material, and more particularly to a composite material laminated with different materials.

  Currently, in the suitcase manufacturing industry, hard shell type suitcases are mainly used, and the types of hard shell suitcases are mainly divided into two types, which are made of a resin (plastic) material or a metal material. Because resin or metal can be processed into special shapes and external shapes, and products made of resin and metal materials are superior in strength, durability and waterproofing than suitcases made of soft materials such as cloth, Welcomed by consumers.

  The hard shell suitcase made of a resin material is also divided into a traditional resin plate and a composite resin plate, and is laminated in a single layer or multilayer form to be layer pressure molded. However, the price of the resin plate and composite resin plate is low, but instead the strength of the structure is inferior, and there is a risk that it will not withstand strong impacts and may be damaged.

  Therefore, in order to improve the above-described deficiency in strength of the resin plate, a multilayer woven resin plate or a composite material woven resin plate woven out with a plastic strip or resin fiber was subsequently developed. Such a woven structure is superior in structure strength to the above-mentioned resin plate, but the material, production, processing and personnel costs of the multi-layer woven resin plate are high, and the manufacturing process is difficult, so the fiber breaks, shifts and bends. The suitcase made with a general multilayer woven resin plate is expensive because the process becomes wrinkled, the pattern is not continuous, and the multilayer woven resin plate tends to become a problem such as limiting the depth of thermoplasticity. , Not for the masses.

  On the other hand, hard shell suitcases made of metal materials are expensive because the metal materials themselves are expensive, and the weight when stacked in multiple layers is high, and sewing is an alternative to save the production cost of expensive hot press molds The process cannot be applied, and the deformation caused by the impact of external force does not automatically recover, so there are problems that are difficult to overcome, such as having to collect and repair them.

  In view of the above problems, in the production of conventional resin or metal hard shell, the cost increases if the strength of the structure is increased, and conversely, if the cost is lowered, the strength of the structure is sacrificed, so the selection of materials is limited. In order to solve various problems, the present invention provides one kind of heterogeneous material laminated composite material, and the heterogeneous material laminated composite material comprises a first layer structure, a central substrate, and a second layer structure in this order. Wherein the first layer structure is a woven fiber layer, a metal layer, a resin layer or a combination thereof, the central substrate is a thermoplastic resin plate, and the second layer structure is a woven fiber layer. And a resin layer, or a woven fiber layer and a non-woven fabric, wherein the woven fiber layer in the first layer structure and the second layer structure is connected to the central substrate via an adhesive layer, respectively, and the first layer Between the structure and the second layer structure Strength difference is 20% or less.

Among them, the thickness of the central substrate is 0.2 to 3.0 mm, the thickness of the woven fiber layer or the nonwoven fabric layer is 0.2 to 0.5 mm, and the thickness of the resin layer However, it is 0.05-0.15 mm, and the thickness of the said metal layer is 0.1-0.5 mm.

  Among them, the material of the central substrate includes polyethylene terephthalate, polypropylene, polyethylene, nylon, polycarbonate or polymethyl methacrylate, and the material of the woven fiber layer is polyethylene fiber, polypropylene fiber, polyethylene terephthalate fiber, carbon fiber, glass fiber. The resin layer material includes polypropylene, nylon, polyurethane, thermoplastic polyurethane, polyethylene terephthalate, Surlyn resin, Pebax resin, polycarbonate or polymethyl methacrylate, and includes a Kevlar fiber, nylon fiber or natural fiber. The material includes aluminum, magnalium alloy, stainless steel, copper, chrome-plated copper, or titanium alloy, and the material of the adhesive layer is a copolymer polyolefin type Copolymerized polyamide, copolymerized polyester, thermoplastic polyurethane, comprising the polyolefin, polyamide, epoxy resin or a polyester based adhesive.

  Among them, the adhesive layer penetrates into the fibers of the woven fiber layer and occupies one third to one half of the volume of the woven fiber layer.

  Among them, some of the fibers of the nonwoven fabric are incorporated into or entangled with some of the fibers of the woven fiber layer.

  Among them, the surface of the resin layer having the first layer structure has a character or pattern that has been subjected to thermal sublimation transfer or printing.

  The present invention further provides a suitcase exterior, a roller skate upper, and a protective gear made of the heterogeneous laminated composite material described above.

  As can be seen from the above description, the present invention has the following advantages:

  1. The present invention uses a central substrate of thermoplastic resin material as a filling layer and a support layer of the main structure of the heterogeneous laminate composite material, so that the structural strength of the resin plate according to the prior art is insufficient and cannot withstand strong impact To solve. The center substrate of the present invention has a wide selection of materials, structural strength, rigidity and impact resistance can be adjusted by different materials, and the center substrate is not a woven structure, and its thickness can be freely adjusted, The material and processing costs are lower than that of a multi-layered woven resin plate composed of only a woven layer, and the manufacturing process is simple, so the market competitiveness is excellent.

  2. Due to the close mechanical strengths of the first layer structure and the second layer structure of the present invention, there are problems such as fiber breakage, misalignment, and bending that occur during subsequent processing and molding, and the pattern does not continue. It becomes difficult to happen. Further, since the woven fiber layer of the present invention is less than the multilayer woven resin plate having the same thickness and strength, the influence on the thermoplastic depth is small.

3. The present invention adopts a metal heterogeneous material laminated composite material obtained by superposing a central substrate and a woven fiber layer with a metal material as an outermost layer, and the central substrate functions as a filling layer and a support layer of the entire composite material. By providing the rigidity and strength of the woven fiber layer as well, the metal composite material of the present invention is superior in overall rigidity and structure strength to the conventional metal laminate, and the weight can be reduced. For example, in the case of an aluminum plate having a specific gravity of 2.7 g / cm ³ and a thickness of 1 mm, the metal dissimilar material laminated composite of the present application has a thickness larger than that of 2700 g per square meter area. The 0.2 mm aluminum plate combines the 0.8 mm thick woven fiber layer and the center substrate, and even with the same thickness of 1 mm, the weight per square meter area in the present invention is only 1400 g, Half the weight can be reduced, and the same structural strength, rigidity and impact resistance can be maintained.

  Furthermore, since the woven fiber layer and the central substrate have the ability to recover to the original shape by themselves after receiving an impact due to an external force, the conventional hard shell suitcase made of a metal material is subject to the impact of an external force. After that, the outer shape cannot be restored to its original shape by itself, and defects that must be recovered and repaired by a contractor can be improved.

  4). The woven fiber layer of the present invention can select different fiber materials, colors, patterns, and knitting methods depending on the application, so that the appearance and the overall structural strength and rigidity of the heterogeneous laminated composite material can be simultaneously enhanced. The effect to do. Further, due to the high specific surface area of the woven fiber layer, it can be easily bonded to other foreign materials by an adhesive / adhesive film and a lamination process.

  5. The present invention is formed by laminating and combining different kinds of materials such as a woven fiber layer, a resin central substrate, or metal, and by combining different materials such as resin and metal, and different structures such as woven material and plate material. Achieves the effect of adjusting the appearance, style, thickness, rigidity and structural strength of the product, and the flexibility of material and structural strength is high.

  6). Because of the woven fiber layer, the present invention does not require hot pressing, and can form a three-dimensional shape directly only by a sewing process. For example, the production of suitcases (shells), bags, etc. can save the production cost of expensive hot press dies, increase the variety of production processes, and the product of the present invention is recessed by the impact of external force. The center substrate and the woven fiber layer have the effect of recovering to the original shape by themselves, and conventional metal hard shell suitcases cannot be restored to the original shape by themselves, and defects that must be recovered and repaired by a contractor Can be improved.

FIG. 1 is a schematic diagram of a laminated structure of a preferred first embodiment of the present invention. FIG. 2a is a cross-sectional view of a first preferred embodiment of the present invention. FIG. 2b is a cross-sectional view of a first preferred embodiment of the present invention. FIG. 2c is a cross-sectional view of a first preferred embodiment of the present invention. FIG. 2d is a cross-sectional view of a first preferred embodiment of the present invention. FIG. 2e is a cross-sectional view of the laminated structure of the second preferred embodiment of the present invention. FIG. 3 is a schematic diagram of a laminated structure of a preferred third embodiment of the present invention.

  As shown in FIG. 1, the heterogeneous material laminated composite material 10a of the first preferred embodiment of the present invention has a structure in which a first layer structure 13a, a central substrate 11a, and a second layer structure 15a are laminated in this order. The first layer structure 13a, the second layer structure 15a, and the central substrate 11a are bonded to each other with an adhesive layer A, respectively.

  Among them, the first layer structure 13a of this embodiment is formed by laminating a woven fiber layer 131a and a resin layer 132a, and the woven fiber layer 131a provides a knitted appearance to the heterogeneous material laminated composite material 10a. In addition, the woven structure can provide the strength of the structure superior to the resin plate. The thickness of the woven fiber layer 131a of this example is 0.2 to 0.5 mm, and the material of the woven fiber layer 131a is polyethylene fiber (Polyethylene, PE), polypropylene fiber (Polypropylene, PP), polyethylene terephthalate. (Polyethylene Terephthalate, PET), carbon fiber, glass fiber, Kevlar fiber, nylon fiber (Nylon), natural fiber (Natural fiber) and the like can be knitted, but is not limited thereto.

  The resin layer 132a covers the surface of the woven fiber layer 131a and provides a glossy texture as a protective layer of the woven fiber layer 131a. Furthermore, a decorative character or pattern can be added to the surface of the resin layer 132a by thermal sublimation transfer or printing. It is preferable that the thickness of the resin layer 132a of the present embodiment is 0.05 to 0.15 mm, and the adhesive layer A is also bonded to each other between the woven fiber layer 131a and the resin layer 132a. can do. The material of the resin layer 132a is polypropylene (Polypropylene, PP), nylon (Nylon), polyurethane (Polyurethane, PU), thermoplastic polyurethane (Thermoplastic Urethane, TPU), polyethylene terephthalate (Polyethylene Terephthalate, PET), trademark ) Resin (trade name) or Pebox (registered trademark) resin (trade name), polycarbonate (Polycarbonate, PC) or polymethylmethacrylate (Polymethylmethacrylate, PMMA) can be used.

  The second layer structure 15a is formed by laminating a woven fiber layer 151a and a resin layer 152a similarly to the first layer structure 13a, and the adhesive layer is also formed between the woven fiber layer 151a and the resin layer 152a. The woven fiber layer 151a and the resin layer 152a may be bonded to each other with the agent layer A, and the materials of the woven fiber layer 131a and the resin layer 132a may be the same.

  The central substrate 11a is one of the main technical features of the present invention, which is sandwiched between the first layer structure 13a and the second layer structure 15a, and the entire structure of the heterogeneous material laminated composite material 10a. Has the effect of filling, supporting, and increasing the strength of the entire structure. The central substrate 11a has a lower cost advantage than a multi-layer woven resin plate that is all laminated with fiber knitting. The central substrate 11a of the present invention preferably employs a recyclable thermoplastic resin together with thermoplastic processing characteristics, has a thickness of 0.2 to 5.0 mm, and is made of polyethylene terephthalate. (Polyethylene Terephthalate, PET), polypropylene (Polypropylene, PP), polyethylene (Polyethylene, PE), nylon (Nylon), polycarbonate (Polycarbonate, PC) or polymethylmethacrylate (Polymethylmethacrylate, PMMA).

  The first layer structure 13a and the second layer structure 15a of the present embodiment are formed by bonding the woven fiber layers 131a and 151a and the central substrate 11a to each other. The material of the adhesive layer A used for bonding includes a copolymerized polyolefin-based, copolymerized polyamide-based, copolymerized polyester-based, or thermoplastic polyurethane-based adhesive depending on the difference in the adhesive interface material.

  The adhesive layer A is applied between each layer mainly in the form of a transparent adhesive or adhesive film, and the selection of the material is selected by bonding materials having the same or similar properties, for example, the woven fiber When the material of the layer 131a is polyethylene fiber and the material of the central substrate 11a is a polyethylene resin plate, the adhesive layer A selects a copolymerized polyolefin-based adhesive that is compatible with the polyethylene fiber and the polyethylene resin plate. By doing so, a more excellent adhesive effect can be achieved.

  In order to balance or reduce the entire structure of the heterogeneous material laminated composite material 10a in order to balance or reduce the stress that the first layer structure 13a and the second layer structure 15a adhere to both sides of the center substrate 11a, preferably, That the compressive strength (compressive strength) or the mechanical strength difference between the first layer structure 13a and the second layer structure 15a is 0 to 20% is equilibrium. The mechanical strength is a strength parameter such as bending strength, tensile strength, and impact strength. When the stress between the first layer structure 13a and the second layer structure 15a is the same or close, problems such as back layer warpage, delamination, and texture compression that occur during subsequent processing and molding can be reduced. . The method of reaching the stress equilibrium between the first layer structure 13a and the second layer structure 15a is based on the selection of the material of each layer, the thickness, or the denier of the woven fiber layer (Denier or D, the number of deniers) To achieve this.

  As an example of the case where the first layer structure 13a and the second layer structure 15a reach a stress equilibrium around the central substrate 11a, the layers of the first layer structure 13a and the second layer structure 15a are the same. In addition to selecting materials and materials having different thicknesses, when combining materials having different materials and thicknesses, for example, the first layer structure 13a has a thickness of 1100 denier and the woven fiber layer 131a has a thickness of 0.2 mm. The resin layer 132a having a thickness of 1 mm is selected, and the second layer structure 15a has a thickness of 900 to 1300 denier, and the woven fiber layer 151a has a thickness of 0.2 to 0.5 mm and a thickness of 0.05 mm correspondingly. The resin layer 132a of ~ 0.15 mm is selected. At this time, the first layer structure 13a and the second layer structure 15a on both sides of the central substrate 11a can reach an equilibrium of mechanical strength, so that the heterogeneous material laminated composite material 10a after hot pressing can be obtained. It can be flat or without warping or creases.

  The woven fiber layers 131a and 151a of the present embodiment and the adhesive layer A can be further joined in a semi-impregnated state. The semi-impregnation means that the adhesive layer A penetrates or impregnates some fibers from one side of the woven fiber layers 131a and 151a, and is about one third of the volume of the woven fiber layers 131a and 151a. In other words, the adhesive layer A does not reach the other surface side of the woven fiber layers 131a and 151a or reaches a little. And, the method of carrying out the semi-impregnation is that after the woven fiber layers 131a and 151a and the adhesive layer A are laminated to each other, the thickness or volume of the adhesive layer A is determined by the woven fiber layers 131a and 151a. By adjusting it to be small and adjusting the hot press parameters during hot pressing, a relatively small amount of the adhesive layer A permeates or impregnates only a part of the woven fiber layers 131a and 151a, and on the other surface side. By not protruding at all or little, the surface of the heterogeneous laminated composite material is kept clean and the situation of adhesive leakage is prevented.

  In the first preferred embodiment of the present invention, the first layer structure 11a and the second layer structure 13a are different from the combination of the woven fiber layers 131a and 151a and the resin layers 132a and 152a in FIG. Referring to 2d, assuming that both the first layer structure 131a and the second layer structure 151a maintain a stress balance, the first layer structure 131a includes the woven fiber layer 131a (shown in 2a and 2c) or the Only the resin layer 132a (shown by 2b and 2d) is adhered to the central substrate 11a, and the second layer structure 151a is adhered to the central substrate 11a only by the woven fiber layer 152a (shown by 2c and 2d). It can be configured, but is not limited to this.

  Referring to 2e of FIG. 2, the second preferred embodiment of the present invention is basically the same as the first embodiment described above, but the difference from the first embodiment is the second layer structure. The non-woven fabric 153a is employed instead of the resin layer 132a in 13a. The nonwoven fabric 153a is fixed by incorporating a part of the fibers of the nonwoven fabric 153a into a part of the fibers of the woven fiber layer 131a by needle punching. In this case, the adhesive layer A can be selectively applied between the nonwoven fabric 153a and the woven fiber layer 131a.

  Referring to FIG. 3, the laminated structure of the heterogeneous material laminated composite material 10b of the preferred third embodiment of the present invention is the same as the first and second embodiments described above, and the first layer structure 13b, The central substrate 11b and the second layer structure 15b are laminated in this order, and are adhered to each other with an adhesive layer B between each layer. The present embodiment and the first and second embodiments described above are connected to each other. The difference is that the first layer structure 13b is a sheet / plate of a metal material and has a thickness in the range of 0.1 to 0.5 mm.

  The material of the first layer structure 13b includes aluminum, magnalium alloy, stainless steel, copper, chrome-plated copper or titanium alloy. The second layer structure 15b is a woven fiber layer 131b, and the material thereof is carbon fiber, glass fiber, Kevlar fiber, polyester fiber, nylon fiber (Nylon Fiber). ) Or natural fiber. The central substrate 11b is a thermoplastic resin plate, and the material thereof is polyethylene terephthalate (PET), polypropylene (Polypropylene, PP), polyethylene (Polyethylene, PE), nylon (Nylon), polycarbonate (Polycarbonate, PC). ) Or polymethylmethacrylate (PMMA).

  Since the first layer structure 13b of the present embodiment is made of a metal material, the material layer is not compatible with the central substrate 11b made of a resin material. More preferably, by using a polyolefin-based, polyamide-based, or polyester-based adhesive, a more excellent bonding effect is achieved. The adhesive layer B used between the second layer structure 15b and the central substrate 11b can employ the same materials as those of the polyolefin, polyamide, and polyester, as well as the first embodiment described above. Adopting the same copolymer polyolefin-based, copolymerized polyamide-based, copolymerized polyester-based, or thermoplastic polyurethane-based adhesives as above has the same good adhesive effect.

  In order to achieve a stress balance between the first layer structure 13b made of the metal material of the present embodiment and the second layer structure 15b made of a resin or natural fiber material, the first substrate is centered on the central substrate 11b. When the layer structure 13b is a thin aluminum plate having a thickness of 0.2 mm, the second layer structure 15b is selected from 1300 to 1800 denier and a woven fiber layer having a thickness of 0.2 to 0.5 mm. Thus, both sides of the central substrate 11b can reach a stress balance, and the heterogeneous material laminated composite material 10b after hot pressing can be flat or free from warping or folds.

In the preferred manufacturing method of each embodiment of the present invention described above, after each layer is laminated with each other, hot pressing parameters are set based on the material and thickness of each selected layer, and the temperature setting of the laminated material is 50 ° C. Immediately after being fed into the hot press machine of No. 1, heated to a temperature set in the range of 150 to 178 ° C., maintained for 3 to 6 minutes under a pressure range of 14 to 20 kg / cm ² , and immediately hot pressed Lower the machine to 50 ° C. and remove the finished product.

  Regarding the application of the present invention, the heterogeneous material laminated composite material of the present invention can be widely applied to products in each region. For example, it can be applied to the exterior of a suitcase, protective gear, roller skate shoes, ice skate shoes, and a laptop computer.

  The preferred embodiment of the present invention has been described above, but the present invention is not limited to such an embodiment, and can be arbitrarily changed or modified without departing from the gist of the present invention.

10a, 10b Heterogeneous laminated composite material 11a, 11b Central substrate 13a, 13b First layer structure 15a, 15b Second layer structure 131a, 151a, 131b Woven fiber layer 132a, 152a Resin layer 153a Non-woven fabric A, B Adhesive layer

Claims (9)

Including the first layer structure, the central substrate, and the second layer structure in this order,
The first layer structure is a woven fiber layer, a metal layer, a resin layer or a combination thereof,
The central substrate is a thermoplastic resin plate;
The second layer structure includes a woven fiber layer and a resin layer, or a woven fiber layer and a nonwoven fabric.
The woven fiber layers in the first layer structure and the second layer structure are respectively connected to the center substrate via an adhesive layer, and mechanical between the first layer structure and the second layer structure. A heterogeneous laminated composite material, wherein the difference in strength is 20% or less. The central substrate has a thickness of 0.2 to 3.0 mm;
The thickness of the woven fiber layer or the nonwoven fabric layer is 0.2 to 0.5 mm,
The heterogeneous material laminate according to claim 1, wherein the resin layer has a thickness of 0.05 to 0.15 mm, and the metal layer has a thickness of 0.1 to 0.5 mm. Composite material. The material of the central substrate includes polyethylene terephthalate, polypropylene, polyethylene, nylon, polycarbonate or polymethyl methacrylate,
The material of the woven fiber layer includes polyethylene fiber, polypropylene fiber, polyethylene terephthalate fiber, carbon fiber, glass fiber, Kevlar fiber, nylon fiber or natural fiber,
The material of the resin layer includes polypropylene, nylon, polyurethane, thermoplastic polyurethane, polyethylene terephthalate, Surlyn resin, Pebax resin, polycarbonate or polymethyl methacrylate,
The material of the metal layer includes aluminum, magnalium alloy, stainless steel, copper, chrome-plated copper or titanium alloy, and the material of the adhesive layer is a copolymer polyolefin, a copolymer polyamide, a copolymer polyester, The heterogeneous material laminated composite material according to claim 1, comprising a thermoplastic polyurethane-based, polyolefin-based, polyamide-based, epoxy resin-based or polyester-based adhesive. The heterogeneous material laminate according to claim 1 or 2, wherein the adhesive layer penetrates into the fibers of the woven fiber layer and occupies one third to one half of the volume of the woven fiber layer. Composite material. The heterogeneous material laminated composite material according to claim 1 or 2, wherein a part of the fibers of the nonwoven fabric is incorporated into or entangled with a part of the fibers of the woven fiber layer.   3. The heterogeneous material laminated composite material according to claim 1, wherein the surface of the resin layer having the first layer structure has a character or pattern printed by thermal sublimation transfer or printed thereon. An exterior of a suitcase made of the heterogeneous material laminated composite material according to claim 1. An upper of a roller skate shoe made of the heterogeneous laminated composite material according to claim 1. A protective gear made of the heterogeneous laminated composite material according to claim 1.