Uni-directional polyester tape and method for producing the same

Abstract

An uni-directinoal polyester tape and method for producing the same are provided. The method for producing the uni-directional polyester tape includes an extruding process, an impregnating process, and a pressing process. The extruding process is implemented by extruding a plurality of polyester chips to form a polyester material that is in a molten state. Each of the polyester chips is formed by polymerizing a dibasic acid composition and a diol composition. The dibasic acid composition includes terephthalic acid and isophthalic acid. The diol composition includes ethylene glycol. A melting temperature of the polyester material is between

Description

[Technical Field]

[0001] This invention relates to a polyester sheet and a method for manufacturing the same, particularly a unidirectional polyester sheet and a method for manufacturing the same. [Previous Technology]

[0002] The thermoplastic resin unidirectional sheet impregnation process is a process in which thermoplastic resin is impregnated into a continuous fiber material to form a composite material. In existing unidirectional sheet manufacturing methods, high-viscosity resins are generally used, resulting in poor melt flowability. This easily leads to poor impregnation, leaving pores between the resin and fibers, poor fiber fuzzing, or even yarn breakage. All of these will cause product defects and affect the physical properties of the finished product.

[0003] Furthermore, in existing methods for manufacturing unidirectional sheets, molten resin material is typically pressed into polyester sheets using a press. However, during the pressing process, the temperature of the press is usually too high (e.g., above 300°C), which can easily cause equipment damage and make maintenance difficult. [Summary of the Invention]

[0004] This invention discloses a polyester sheet and its manufacturing method, which is mainly used to improve the problem of poor resin impregnation in the existing unidirectional sheet manufacturing method and the problem of equipment damage and maintenance difficulties caused by excessively high temperature of the press.

[0005] One embodiment of the present invention discloses a method for manufacturing a unidirectional polyester sheet, comprising: an extrusion step of extruding a plurality of polyester granules to form a polyester resin material in a molten state; wherein each of the polyester granules is obtained by polymerization of a diacid composition and a diol composition; wherein, based on a total weight of 100 wt% of the diacid composition, the diacid composition comprises 84 wt% to 99.9 wt% of terephthalic acid and 0.1 wt% to 16 wt% of isophthalic acid; wherein, based on a total weight of 100 wt% of the diol composition, the diol composition comprises 84 wt% to 98.8 wt% of isophthalic acid. The polyester resin material comprises 100 wt% ethylene glycol; wherein the melting point temperature of the polyester resin material is between 180°C and 256°C; an impregnation step in which a plurality of fiber materials are impregnated in the molten polyester resin material; and a pressing step in which the polyester resin material impregnated with the fiber materials is pressed with a pressing machine to form a unidirectional polyester sheet; wherein the pressing machine comprises two pressing tracks, and the two pressing tracks are capable of pressing the polyester resin material impregnated with the fiber materials along a mechanical direction; wherein each pressing track is made of Teflon or steel, and a pressing temperature of each pressing track is not less than the melting point temperature of the polyester resin material + 5°C, and the pressing temperature is between 200°C and 270°C; wherein the plurality of fiber materials are arranged along the mechanical direction; wherein, based on a total weight of 100 wt% of the unidirectional polyester sheet, the content of the polyester resin material is between 30 wt% and 50 wt%, and the content of the fiber material is between 50 wt%. Between wt% and 70 wt%.

[0006] Preferably, each of the press-fitted tracks is made of Teflon, the pressing temperature of the press-fitted tracks is between 200°C and 230°C, and the melting point temperature of the polyester resin material is between 185°C and 220°C.

[0007] Preferably, the inherent viscosity of the polyester resin material is between 0.6 dL / g and 0.95 dL / g.

[0008] Preferably, each of the fiber materials is a glass fiber, and the average diameter of the plurality of fiber materials is between 10 micrometers and 25 micrometers.

[0009] Preferably, each of the fiber materials is a carbon fiber, and the average diameter of the plurality of fiber materials is between 5 micrometers and 10 micrometers.

[0010] Preferably, the thickness of the unidirectional polyester sheet is between 0.08 mm and 0.25 mm, and the width of the unidirectional polyester sheet in a transverse direction is between 1 cm and 150 cm.

[0011] Preferably, based on the total weight of the diol composition being 100 wt%, the diol composition further comprises 1 wt% to 5 wt% neopentyl glycol.

[0012] Preferably, based on the total weight of the diol composition being 100 wt%, the diol composition further comprises 0.2 wt% to 11 wt% of diethylene glycol.

[0013] Preferably, the polyester resin material has a viscosity between 100 Pa·s and 1,300 Pa·s at a temperature between 200°C and 300°C.

[0014] One embodiment of the present invention discloses a unidirectional polyester sheet, which is obtained by performing the manufacturing method of the unidirectional polyester sheet as claimed in claim 1.

[0015] In summary, the unidirectional polyester sheet and its manufacturing method provided by the present invention can improve the problems of poor resin impregnation and equipment damage and maintenance difficulties caused by excessively high temperature of the press in the existing unidirectional sheet manufacturing method by means of the technical solutions of "the total weight of the diacid composition is 100 wt%, the diacid composition contains 84 wt% to 99.9 wt% of terephthalic acid and 0.1 wt% to 16 wt% of isophthalic acid" and "the melting point temperature of the polyester resin material is between 180°C and 256°C".

[0016] To further understand the features and technical content of the present invention, please refer to the following detailed description and drawings of the present invention. However, these descriptions and drawings are only used to illustrate the present invention and are not intended to limit the scope of protection of the present invention in any way.

Implementation Method

[0017] The following specific embodiments illustrate the implementation of the "unidirectional polyester sheet and its manufacturing method" disclosed in this invention. Those skilled in the art can understand the advantages and effects of this invention from the content disclosed in this specification. This invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of this invention. Furthermore, the accompanying drawings of this invention are for simple illustrative purposes only and are not depictions of actual dimensions; this is stated in advance. The following embodiments will further describe the relevant technical content of this invention in detail, but the disclosed content is not intended to limit the scope of protection of this invention.

[0018] It should be understood that although terms such as “first,” “second,” and “third” may be used herein to describe various components or signals, these components or signals should not be limited by these terms. These terms are primarily used to distinguish one component from another, or one signal from another. In addition, the term “or” as used herein may include, as appropriate, any combination of any one or more of the associated listed items.

[0019] Please refer to Figure 1, which is a flowchart of a method for manufacturing a unidirectional polyester sheet according to an embodiment of the present invention. The present invention provides a method for manufacturing a unidirectional polyester sheet. The method includes an extrusion step S110, an impregnation step S120, and a pressing step S130. Of course, the method for manufacturing a unidirectional polyester sheet may include other steps as needed, and the present invention does not limit this.

[0020] In the extrusion step S110, a plurality of polyester granules are extruded to form a polyester resin material 1 in a molten state. Each of the polyester granules is obtained by polymerization of a diacid composition and a diol composition. Based on a total weight of 100 wt% of the diacid composition, the diacid composition contains 84 wt% to 99.9 wt% of terephthalic acid and 0.1 wt% to 16 wt% of isophthalic acid. Based on a total weight of 100 wt% of the diol composition, the diol composition contains 84 wt% to 98.8 wt% of ethylene glycol. The weight ratio between the diacid composition and the diol composition may be between 1:1.5 and 1.5:1, but the present invention is not limited thereto. Preferably, the weight ratio between the diacid composition and the diol composition may be approximately 1:1.

[0021] By including isophthalic acid in the dicarboxylic acid composition, the melting point temperature of the polyester resin material 1 can be effectively reduced. Specifically, the melting point temperature of the polyester resin material 1 is between 180°C and 256°C. Preferably, the melting point temperature of the polyester resin material 1 is between 180°C and 254.31°C. More preferably, the melting point temperature of the polyester resin material 1 is between 189.97°C and 254.31°C. The intrinsic viscosity of the polyester resin material 1 may be between 0.6 dL / g and 0.95 dL / g, but the present invention is not limited thereto. It is worth mentioning that the intrinsic viscosity of the polyester resin material 1 is measured under the ASTM D4603 standard.

[0022] In one embodiment, the diol composition further comprises neopentyl glycol, wherein the neopentyl glycol content is between 1 wt% and 5 wt% based on a total weight of 100 wt% of the diol composition. In one embodiment, the diol composition further comprises diethylene glycol, wherein the diethylene glycol content is between 0.2 wt% and 11 wt% based on a total weight of 100 wt% of the diol composition. Neopentyl glycol can improve the heat resistance, UV resistance, and mechanical properties of the polyester resin material 1, and improve the transparency and gloss of the polyester resin material 1. Diethylene glycol can improve the flexibility, processability, and crystallinity of the polyester resin material 1.

[0023] Please refer to Figure 2, which is a graph showing the relationship between the viscosity and temperature of the polyester resin according to an embodiment of the present invention. In Figure 2, temperature curves of various polyester resin materials 1 (i.e., resin A, resin B, resin C, and resin D) are measured. Resins A, B, C, and D are obtained by polymerization of the diacid composition and the diol composition. As can be seen from Figure 2, the polyester resin material 1 has a viscosity between 100 Pa·s and 1,300 Pa·s at temperatures between 200°C and 300°C.

[0024] In resin A, based on a total weight of 100 wt% of the diacid composition, the diacid composition comprises 84 wt% terephthalic acid and 16 wt% isophthalic acid, and based on a total weight of 100 wt% of the diol composition, the diol composition comprises 84 wt% ethylene glycol, 5 wt% neopentyl glycol, and 11 wt% diethylene glycol. The polyester resin material 1 (i.e., resin A) has a viscosity between 180 Pa·s and 1,280 Pa·s at a temperature between 200°C and 285°C.

[0025] In resin B, based on a total weight of 100 wt% of the diacid composition, the diacid composition comprises 88 wt% terephthalic acid and 12 wt% isophthalic acid, and based on a total weight of 100 wt% of the diol composition, the diol composition comprises 95 wt% ethylene glycol, 3 wt% neopentyl glycol, and 2 wt% diethylene glycol. The polyester resin material 1 (i.e., resin B) has a viscosity between 210 Pa·s and 860 Pa·s at a temperature between 230°C and 291°C.

[0026] In resin C, based on a total weight of 100 wt% of the diacid composition, the diacid composition comprises 95.5 wt% terephthalic acid and 4.5 wt% isophthalic acid, and based on a total weight of 100 wt% of the diol composition, the diol composition comprises 97.2 wt% ethylene glycol, 2 wt% neopentyl glycol, and 0.8 wt% diethylene glycol. The polyester resin material 1 (i.e., resin C) has a viscosity between 380 Pa·s and 860 Pa·s at a temperature between 257°C and 291°C.

[0027] In resin D, based on a total weight of 100 wt% of the diacid composition, the diacid composition comprises 99.9 wt% terephthalic acid and 0.1 wt% isophthalic acid, and based on a total weight of 100 wt% of the diol composition, the diol composition comprises 98.8 wt% ethylene glycol, 1 wt% neopentyl glycol, and 0.2 wt% diethylene glycol. The polyester resin material 1 (i.e., resin D) has a viscosity between 540 Pa·s and 860 Pa·s at a temperature between 265°C and 291°C.

[0028] In the impregnation step S120, a plurality of fiber materials 2 are impregnated in the polyester resin material 1 in a molten state. Specifically, the polyester resin material 1 in a molten state can be extruded to an extrusion die (not shown) to impregnate a plurality of fiber materials 2, but the present invention does not limit the manner in which a plurality of fiber materials 2 are impregnated in the polyester resin material 1 in a molten state.

[0029] In one embodiment, each of the fiber materials 2 is a glass fiber, and the average diameter of the plurality of fiber materials 2 is between 10 micrometers and 25 micrometers, but the present invention is not limited thereto. In one embodiment, each of the fiber materials 2 is a carbon fiber, and the average diameter of the plurality of fiber materials 2 is between 5 micrometers and 10 micrometers, but the present invention is not limited thereto.

[0030] In the pressing step S130, the polyester resin material 1 impregnated with the fiber material 2 is pressed using a pressing machine P to form a unidirectional polyester sheet 100. Based on a total weight of 100 wt% for the unidirectional polyester sheet 100, the content of the polyester resin material 1 is between 30 wt% and 50 wt%, and the content of the fiber material 2 is between 50 wt% and 70 wt%. Preferably, based on a total weight of 100 wt% for the unidirectional polyester sheet 100, the content of the polyester resin material 1 is between 35 wt% and 45 wt%, and the content of the fiber material 2 is between 55 wt% and 65 wt%. However, the present invention is not limited thereto.

[0031] The pressing machine P includes two pressing tracks P1, and the two pressing tracks P1 can press the polyester resin material 1 impregnated with the fiber material 2 along a mechanical direction MD. Each pressing track P1 is made of Teflon or steel, and the pressing temperature of each pressing track P1 is not less than the melting point temperature of the polyester resin material 1 + 5°C, and the pressing temperature is between 200°C and 270°C.

[0032] Preferably, each of the pressed tracks P1 is made of Teflon, the pressing temperature of the pressed tracks P1 is between 200°C and 230°C, and the melting point temperature of the polyester resin material 1 is between 185°C and 220°C. More preferably, the melting point temperature of the polyester resin material 1 is between 189.97°C and 219.54°C.

[0033] The plurality of said fiber materials 2 are arranged along the mechanical direction MD. Specifically, the plurality of said fiber materials 2 in the unidirectional polyester sheet 100 may be arranged only in the same direction (such as the mechanical direction MD), but the present invention is not limited thereto. The thickness T of the unidirectional polyester sheet 100 is between 0.08 mm and 0.25 mm, and the width W of the unidirectional polyester sheet in a transverse direction TD is between 1 cm and 150 cm, but the present invention is not limited thereto. The transverse direction is perpendicular to the mechanical direction.

[0034] An embodiment of the present invention provides a unidirectional polyester sheet 100, which may be obtained by performing the aforementioned manufacturing method of unidirectional polyester sheet, but the present invention is not limited thereto.

[0035] [Experimental Data Test]

[0036] Hereinafter, the present invention will be described in detail with reference to Examples 1 to 8 and Comparative Examples 1 and 2. However, the following examples are only provided to help understand the present invention, and the scope of the present invention is not limited to these examples.

[0037] Example 1: The polyester granules contain 60 wt% glass fiber and 40 wt% resin A, which is obtained by polymerizing a diacid composition and a diol composition. The diacid composition contains 84 wt% terephthalic acid and 16 wt% isophthalic acid, and the diol composition contains 84 wt% ethylene glycol, 5 wt% neopentyl glycol and 11 wt% diethylene glycol.

[0038] Example 2: The polyester granules contain 60 wt% glass fiber and 40 wt% resin B, which is obtained by polymerizing a diacid composition and a diol composition. The diacid composition contains 88 wt% terephthalic acid and 12 wt% isophthalic acid, and the diol composition contains 95 wt% ethylene glycol, 3 wt% neopentyl glycol and 2 wt% diethylene glycol.

[0039] Example 3: The polyester granules contain 60 wt% glass fiber and 40 wt% resin C, which is obtained by polymerizing a diacid composition and a diol composition. The diacid composition contains 95.5 wt% terephthalic acid and 4.5 wt% isophthalic acid, and the diol composition contains 97.2 wt% ethylene glycol, 2 wt% neopentyl glycol and 0.8 wt% diethylene glycol.

[0040] Example 4: The polyester granules contain 60 wt% glass fiber and 40 wt% resin D, which is obtained by polymerizing a diacid composition and a diol composition. The diacid composition contains 99.9 wt% terephthalic acid and 0.1 wt% isophthalic acid, and the diol composition contains 98.8 wt% ethylene glycol, 1 wt% neopentyl glycol and 0.2 wt% diethylene glycol.

[0041] Example 5: The polyester granules contain 60 wt% carbon fiber and 40 wt% resin A. Example 6: The polyester granules contain 60 wt% carbon fiber and 40 wt% resin B. Example 7: The polyester granules contain 60 wt% carbon fiber and 40 wt% resin C. Example 8: The polyester granules contain 60 wt% carbon fiber and 40 wt% resin D. Comparative Example 1: The polyester granules contain 60 wt% carbon fiber and 40 wt% PA66 resin. Comparative Example 2: The polyester granules contain 60 wt% carbon fiber and 40 wt% PA66 resin.

[0042] The component ratio formulations and impregnation and pressing conditions of the unidirectional polyester sheets of Examples 1 to 8 and Comparative Examples 1 and 2 are shown in Table 1 below, and the components and melting point temperatures of resin A, resin B, resin C and resin D are shown in Table 2 below.

[0043] [Table 1: Component ratio formulations and impregnation and pressing conditions for unidirectional polyester sheets in exemplary and comparative examples] project Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Comparative Example 1 Comparative Example 2 Fiber materials Glass fiber content (wt%) 60 60 60 60 0 0 0 0 0 0 Carbon fiber content (wt%) 0 0 0 0 60 60 60 60 60 60 (Polyester) Resin Material Resin A content (wt%) 40 0 0 0 40 0 0 0 0 0 Resin B content (wt%) 0 40 0 0 0 40 0 0 0 0 Resin C content (wt%) 0 0 40 0 0 0 40 0 0 0 Resin D content 0 0 0 40 0 0 0 40 0 0 PA66 resin content (wt%) 0 0 0 0 0 0 0 0 40 40 impregnated Resin feed type (granular) (granular) (granular) (granular) (granular) (granular) (granular) (granular) (granular) (Powder) Extrusion die temperature 200℃ 230℃ 255℃ 265℃ 200℃ 230℃ 255℃ 265℃ 300℃ none Electrostatic adsorption powder none none none none none none none none none yes Processability good good good good good good good good Defects (broken yarn, hairiness) good Pressing Temperature of pressed track (°C) 200 230 255 270 200 230 255 265 300 300 Fiber weight per unit area (g / m²) 2 ) 150 150 150 150 100 100 125 125 125 125 Thickness of unidirectional polyester sheet (mm) 0.12 0.1 0.15 0.12 0.1 0.15 0.1 0.1 0.12 0.12 Pressed track material Teflon Teflon steel steel Teflon Teflon steel steel steel steel

[0044] [Table 2 Composition and melting point temperature of resin A, resin B, resin C and resin D] project Resin A Resin B Resin C Resin D Dicarboxylic acid composition Terephthalic acid content (wt%) 84 88 95.5 99.9 Isophthalic acid content (wt%) 16 12 4.5 0.1 Diol composition Ethylene glycol content (wt%) 84 95 97.2 98.8 Neopentyl glycol content (wt%) 5 3 2 1 Diethylene glycol content (wt%) 11 2 0.8 0.2 Melting point temperature (°C) 189.97 219.54 241.60 254.31

[0045] [Discussion of Test Results]

[0046] As can be seen from Examples 1 to 8, by using resin A, resin B, resin C, or resin D as the polyester resin material, the extrusion die temperature and the pressing track temperature can be relatively low. Furthermore, the polyester material can be fed in granular form, thus eliminating the need for electrostatic adsorption of the powder. After pressing, the fiber weight per unit area of ​​the unidirectional polyester sheet can be between 100 g / m² and 150 g / m², and the thickness of the unidirectional polyester sheet can be between 0.1 mm and 0.15 mm. In Comparative Examples 1 and 2, nylon 66 (i.e., PA66) is used as the resin material. However, the extrusion die temperature and the pressing track temperature in Comparative Example 1 are both higher, and in Comparative Example 2, nylon 66 is fed in powder form, therefore electrostatic adsorption of the powdered nylon 66 onto the fiber material is required, and it is not extruded through the extrusion die.

[0047] [Beneficial Effects of the Embodiments of the Invention]

[0048] In summary, the unidirectional polyester sheet and its manufacturing method provided by the present invention can improve the problems of poor resin impregnation and equipment damage and maintenance difficulties caused by excessively high temperature of the press in the existing unidirectional polyester sheet manufacturing method by means of the technical solutions of "the total weight of the diacid composition is 100 wt%, the diacid composition contains 84 wt% to 99.9 wt% of terephthalic acid and 0.1 wt% to 16 wt% of isophthalic acid" and "the melting point temperature of the polyester resin material is between 180°C and 256°C".

[0049] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Therefore, all equivalent technical changes made based on the description and drawings of the present invention are included within the protection scope of the present invention. [Simplified Explanation of the Diagram]

[0050] Figure 1 is a flowchart of a method for manufacturing unidirectional polyester sheets according to an embodiment of the present invention.

[0051] Figure 2 is a graph showing the relationship between the viscosity and temperature of the polyester resin in an embodiment of the present invention.

[0052] Figure 3 is a three-dimensional schematic diagram of the pressing machine in the manufacturing method of unidirectional polyester sheet according to an embodiment of the present invention.

[0053] Figure 4 is a three-dimensional schematic diagram of a unidirectional polyester sheet according to an embodiment of the present invention.

Claims

1. A method for manufacturing a unidirectional polyester sheet, comprising: an extrusion step, wherein a plurality of polyester granules are extruded to form a polyester resin material in a molten state; wherein, Each of the polyester particles is obtained by polymerization of a diacid composition and a diol composition; wherein, based on a total weight of 100 wt% for the diacid composition, the diacid composition is composed of 84 wt% to 99.9 wt% of terephthalic acid and 0.1 wt% to 16 wt% of isophthalic acid; wherein, based on a total weight of 100 wt% for the diol composition, the diol composition is composed of 84 wt% to 98.8 wt% of ethylene glycol, 1 wt% to 5 wt% of neopentyl glycol and 0.2 wt% to 11 wt% of diethylene glycol; wherein, the melting point temperature of the polyester resin material is between 180°C and 256°C. The process includes an impregnation step in which a plurality of fiber materials are impregnated in a molten polyester resin material; and a pressing step in which the polyester resin material impregnated with the fiber materials is pressed with a pressing machine to form a unidirectional polyester sheet; wherein the pressing machine comprises two pressing tracks, and the two pressing tracks are capable of pressing the polyester resin material impregnated with the fiber materials along a mechanical direction; wherein each pressing track is made of Teflon or steel, and the pressing temperature of each pressing track is not less than the melting point temperature of the polyester resin material + 5°C, and the pressing temperature is between 200°C and 270°C; wherein the plurality of fiber materials are arranged along the mechanical direction; wherein, based on a total weight of 100 wt% for the unidirectional polyester sheet, the content of the polyester resin material is between 30 wt% and 50 wt%, and the content of the fiber material is between 50 wt% and 70 wt%.

2. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, Each of the press-fitted tracks is made of Teflon, the pressing temperature of the press-fitted tracks is between 200°C and 230°C, and the melting point temperature of the polyester resin material is between 185°C and 220°C.

3. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, The inherent viscosity of the polyester resin material is between 0.6 dL / g and 0.95 dL / g.

4. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, Each of the fiber materials is a glass fiber, and the average diameter of the plurality of fiber materials is between 10 micrometers and 25 micrometers.

5. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, Each of the fiber materials is a carbon fiber, and the average diameter of the plurality of fiber materials is between 5 micrometers and 10 micrometers.

6. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, The thickness of the unidirectional polyester sheet is between 0.08 mm and 0.25 mm, and the width of the unidirectional polyester sheet in a transverse direction is between 1 cm and 150 cm.

7. A method for manufacturing a unidirectional polyester sheet as described in claim 1, wherein, The polyester resin material has a viscosity between 100 Pa·s and 1,300 Pa·s at a temperature between 200°C and 300°C.

8. A unidirectional polyester sheet obtained by performing a method for manufacturing a unidirectional polyester sheet as claimed in claim 1.

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