【発明の詳細な説明】[Detailed description of the invention]
本発明は、熱可塑性樹脂積層板の製造法の改良
に関する。
従来、熱収縮、剛性を改良した熱可塑性樹脂積
層板として、適当な溶媒に溶かした熱可塑性樹脂
或は熱溶融した熱可塑性樹脂を基材に含浸、乾燥
したプリプレグを積層成形してなるものが提案さ
れている（実願昭51−39157号（実開昭52−
127784号公報）が、この積層板は熱間剛性および
耐熱性が劣る。これらを改良したものとして、特
願昭53−65548号（特開昭54−1560765号公報）に
示すように、熱可塑性樹脂含浸プリプレグ層の両
表面に熱硬化性樹脂含浸ガラス織布プリプレグを
１枚づつ置いて成形したものがあり、熱間剛性、
耐溶剤性は優れている。しかし、この積層板は、
熱硬化性樹脂含浸ガラス織布基材層と熱可塑性樹
脂含浸基材層との層間接着強度が弱いために積層
板として大きな問題点となつている。
本発明は、この問題点を解決し、熱硬化性樹脂
含浸基材層と熱可塑性樹脂含浸基材層との接着強
度を改善した積層板の製造法を提供するものであ
る。
本発明は、基材に熱可塑性樹脂を含浸したプリ
プレグ層の両表面に少なくとも有機或は無機繊維
の不織布基材に熱硬化性樹脂を含浸したプリプレ
グを載置し、これらを積層成形することによつ
て、上記の問題点を解決したものである。不織布
は密度が小さく表面が毛羽立つているので、この
毛羽立つた繊維が熱可塑性樹脂中に投錨した状態
となり、熱可塑性樹脂含浸基材層と熱硬化性樹脂
含浸不織布基材層との接着強度の向上に作用して
いるものと推定される。
尚、熱可塑性樹脂含浸基材層の両表面が不織布
基材層のみのときには、曲げ剛性が十分でないの
で、更に、ガラス織布基材に熱硬化性樹脂を含浸
したプリプレグを重ねて積層成形してもよい。
次に本発明の実施例を示す。
実施例 １
ガラス不織布基材にポリサルフオン樹脂溶液を
樹脂量50重量％で含浸乾燥して得たプリプレグを
所定枚数重ね、該プリプレグの両表面にガラス不
織布にエポキシ樹脂溶液を含浸乾燥して得たプリ
プレグを置き160℃〜170℃にて加熱加圧して1.6
mm厚の積層板を得た（発明品１）。
実施例 ２
ガラス不織布基材にポリサルフオン樹脂溶液を
樹脂量50重量％で含浸乾燥して得たプリプレグを
所定枚数重ね、該プリプレグの両表面にガラス不
織布にエポキシ樹脂を含浸乾燥して得たプリプレ
グ１枚づつ置き、更にその両表面にガラス織布に
エポキシ樹脂を含浸乾燥して得たプリプレグを１
枚づつ置き160℃〜170℃にて加熱加圧して1.6mm
厚の積層板を得た（発明品２）。
従来例
ガラス不織布基材にポリサルフオン樹脂溶液を
樹脂量50重量％で含浸乾燥して得たプリプレグを
所定枚数重ね、該プリプレグの両表面にガラス織
布にエポキシ樹脂を含浸乾燥して得たプリプレグ
を重ねて160℃〜170℃に加熱加圧して1.6mm厚の
積層板を得た（従来品）。
上記各積層板の性能を第１表に示す。
層間接着強度は、エポキシ樹脂含浸ガラス不織
布基材層を積層板と直角方向に剥離（引き剥しク
ロスヘツド速度：0.5mm／分）したときの測定値
であり、曲げ強度はJISC−6481による測定値で
ある。
The present invention relates to an improved method for manufacturing thermoplastic resin laminates. Conventionally, thermoplastic resin laminates with improved heat shrinkage and rigidity have been produced by laminating and molding prepregs that have been impregnated into a base material with a thermoplastic resin dissolved in an appropriate solvent or a thermoplastic resin that has been melted and then dried. It has been proposed (Utility Application No. 51-39157
127784), but this laminate has poor hot rigidity and heat resistance. As an improvement on these, as shown in Japanese Patent Application No. 53-65548 (Japanese Unexamined Patent Publication No. 54-1560765), one layer of glass woven fabric prepreg impregnated with a thermosetting resin is applied to both surfaces of the prepreg layer impregnated with a thermoplastic resin. There are products that are molded by placing one sheet at a time, and the hot rigidity,
Excellent solvent resistance. However, this laminate
The weak interlayer adhesion strength between the thermosetting resin-impregnated glass woven base layer and the thermoplastic resin-impregnated base layer poses a major problem as a laminate. The present invention solves this problem and provides a method for manufacturing a laminate in which the adhesive strength between the thermosetting resin-impregnated base layer and the thermoplastic resin-impregnated base layer is improved. The present invention involves placing at least a prepreg made of a nonwoven fabric base material of organic or inorganic fibers impregnated with a thermosetting resin on both surfaces of a prepreg layer having a base material impregnated with a thermoplastic resin, and then laminating and molding these. Therefore, the above problems are solved. Since nonwoven fabric has a low density and a fluffy surface, these fluffy fibers become anchored in the thermoplastic resin, improving the adhesive strength between the thermoplastic resin-impregnated base material layer and the thermosetting resin-impregnated nonwoven fabric base layer. It is presumed that this is acting on the In addition, when both surfaces of the thermoplastic resin-impregnated base material layer are only nonwoven fabric base material layers, the bending rigidity is insufficient, so a prepreg impregnated with a thermosetting resin is further stacked on the glass woven fabric base material and laminated. It's okay. Next, examples of the present invention will be shown. Example 1 A predetermined number of prepregs obtained by impregnating and drying a polysulfone resin solution in a resin amount of 50% by weight on a glass nonwoven fabric base material are stacked, and prepregs obtained by impregnating and drying a glass nonwoven fabric with an epoxy resin solution on both surfaces of the prepreg are prepared. Heat and pressurize at 160°C to 170°C to 1.6
A laminate with a thickness of mm was obtained (invention product 1). Example 2 A predetermined number of prepregs obtained by impregnating and drying a polysulfone resin solution in a resin amount of 50% by weight on a glass nonwoven fabric base material were stacked, and prepreg 1 was obtained by impregnating and drying a glass nonwoven fabric with an epoxy resin on both surfaces of the prepreg. Place one sheet at a time, and then add 1 piece of prepreg obtained by impregnating and drying a glass woven cloth with epoxy resin on both surfaces.
Heat and press at 160°C to 170°C to 1.6mm.
A thick laminate was obtained (invention product 2). Conventional example: A predetermined number of prepregs obtained by impregnating and drying a polysulfone resin solution in a resin amount of 50% by weight on a glass nonwoven fabric base material are stacked, and on both surfaces of the prepregs, prepregs obtained by impregnating and drying a glass woven fabric with an epoxy resin are applied. They were stacked together and heated and pressed at 160°C to 170°C to obtain a 1.6 mm thick laminate (conventional product). Table 1 shows the performance of each of the above laminates. The interlayer adhesion strength is the value measured when the epoxy resin-impregnated glass nonwoven base material layer is peeled off in the direction perpendicular to the laminate (peel crosshead speed: 0.5 mm/min), and the bending strength is the value measured according to JISC-6481. be.
【表】
上述のように本発明によれば、熱可塑性樹脂含
浸基材層と熱硬化性樹脂含浸基材層との層間接着
力を従来の２倍程度に向上させることができ、積
層板としての重要な問題点を解決した点、極めて
工業的価値の大なるものである。[Table] As described above, according to the present invention, the interlayer adhesion between the thermoplastic resin-impregnated base material layer and the thermosetting resin-impregnated base material layer can be improved to about twice that of the conventional one, and the laminate can be used as a laminate. It is of great industrial value as it solves an important problem.