CN101010177A - 薄层加强材料 - Google Patents

薄层加强材料 Download PDF

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CN101010177A
CN101010177A CNA2006800007112A CN200680000711A CN101010177A CN 101010177 A CN101010177 A CN 101010177A CN A2006800007112 A CNA2006800007112 A CN A2006800007112A CN 200680000711 A CN200680000711 A CN 200680000711A CN 101010177 A CN101010177 A CN 101010177A
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thin
reinforcing material
reinforced
matrix
layer
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菅原正隆
菅原寿秀
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Maru Eight Export Trading Corp
Maruhachi Corp
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Maru Eight Export Trading Corp
Maruhachi Corp
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Abstract

本发明提供既保持薄的、轻型且具有挠性的薄层基体的厚度或重量、挠性等特征、又提高拉伸强度、撕裂强度等的机械特性的薄层加强材料。本发明的薄层加强材料(10)是由使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束(1)利用粘接性树脂(11)浸渍的带状体构成的薄层的加强带，通过将该加强带(10)粘合在作为加强对象的被加强基体(20)上来加强该被加强基体(20)的上述机械特性。

Description

薄层加强材料
技术领域
本发明涉及强化轻型的、薄的且具有挠性的被加强基体的机械特性的薄层加强材料。
背景技术
目前作为复合材料用的中间材料，广泛使用的是将碳纤维等原封不动地浸渍在成为基体的热固性树脂或热可塑性树脂中而形成的带(参照专利文献1)。
并且，实际也使用将强化纤维浸渍在未硬化的热固性树脂中、绕在或粘在柱子等建筑物的主要部位上等进行强化的带。
而且，作为复合材料的中间材料也发表了通过将强化纤维开纤得到的超薄的纤维加强材料(参照专利文献2)。
利用这样普通的纤维强化聚合物复合材料的中间体制造的成型品的特征是虽然轻但却是刚体、具有高机械特性，近年来开始用于以飞机部件为主的各种用途。
专利文献1：日本特开2003-165851号公报
专利文献2：国际公开第2005/002819号小册子
发明内容
如上所述，目前的纤维强化聚合物复合材料虽然可以得到高机械特性，但在该高机械特性中很难兼备薄型和挠性。因此，相对轻型的且具有挠性的薄层基体，作为既保持其特性又强化机械特性的加强材料不能使用现有的复合材料的中间体。
例如，作为需要既保持基体的轻型性、薄型、挠性等、又兼备撕裂强度等高的机械特性的基体，例如有帆船的帆。对于帆船的帆，虽然理想的材料有针织帆布，但比赛用的帆船需要在各种条件的风中发挥最大限度的船速，因此，对该帆除了形状以外还要求具有轻型、撕裂强度高、足够的挠性以及耐折叠性。在用目前的复合材料用中间材料的带制作这样的帆的情况下，帆的厚度增加的同时，重量也增加，也有损于挠性和耐折叠性。并且，由于多次使用过量的强化纤维，增加了这部分的成本。
如上所述，目前虽然有绕在或粘合在建筑物的主要部分上等、强化建筑物的抗震的带，但由于其强化对象为柱子等的刚体，并且目的是抗震强化，在这点上，该带不适合作为既保持轻型且具有挠性的薄层基体的特性、又强化机械特性的加强材料进行使用。
并且，目前虽然发表了通过将强化纤维开纤得到的超薄的纤维加强材料，但文献中根本没有提到作为既保持轻型且具有挠性的薄层基体的特性、又强化机械特性的加强材料进行使用的想法。
本发明为了解决上述现有的问题，目的是提供既保持薄的、轻型且具有挠性的薄层基体的厚度或重量、挠性等特征、又提高机械特性的薄层加强材料。
为了解决上述的问题，本发明的薄层加强材料是粘合在被加强基体上、强化该基体的机械特性的薄层的加强材料，由使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束(单糸束)浸渍在粘接性树脂而成的带状体构成。
这样，不使上述被加强基体的重量或厚度等特性发生大的变化、就可以提高该被加强基体的机械特性。
而且，根据本发明的薄层加强材料，上述被加强基体是轻型的、薄的且具有挠性特性。
这样，在保持轻型的、薄的且具有挠性特性的被加强基体的特性的状态下，还可提高该被加强基体的机械特性。
而且，根据本发明的薄层加强材料，上述被加强基体为片状体。
这样，在保持轻型的、薄的且具有挠性特性的片状被加强基体的特性的状态下，还可提高其机械特性。
而且，根据本发明的薄层加强材料，上述粘接性树脂是热熔型树脂。
这样，可通过加热压接使该薄层加强材料与上述被加强基体接合。
而且，根据本发明的薄层加强材料，将剥离型带至少粘合在该薄层加强材料的一面。
这样，可卷起该薄层加强材料进行保管，因此其保管方法简便，并且，将薄层加强材料粘合在被加强基体上时也可容易进行该处理。
而且，根据本发明的薄层加强材料，上述强化纤维是碳纤维。
这样，利用碳纤维的高比强度、高比弹性模量，可以有效地提高该薄层加强材料的机械特性。
而且，根据本发明的薄层加强材料，在上述强化纤维单丝束的层中，该强化纤维向单轴方向排列。
这样，不使上述被加强基体的重量或厚度等特性发生大的变化、就可以提高该被加强基体的定向轴方向的机械特性。而且，通过适当地选择该薄层加强材料向被加强基体的接合设置，可自由选择被加强基体的机械特性的强化方向。
而且，根据本发明的薄层加强材料，以使该薄层加强材料的强化纤维的排列方向向着一个方向的方式，将该薄层加强材料粘在上述被加强基体上。
这样，不使上述被加强基体的重量或厚度等特性发生大的变化、就可以提高该被加强基体的特定方向的机械特性。
而且，根据本发明的薄层加强材料，以使该薄层加强材料的强化纤维的排列方向向着不同的方向的方式，将该薄层加强材料重叠粘在上述被加强基体上。
这样，不使上述被加强基体的重量或厚度等特性发生大的变化、就可以提高该被加强基体的多个方向的机械特性。
而且，根据本发明的薄层加强材料，上述被加强基体的主要构成成分是双向拉伸薄膜。
这样，利用双向拉伸薄膜的强韧性可以更容易提供气密性好、轻型、薄的且具有挠性的加强体。该加强体尤其适用于帆用材料。
而且，根据本发明的薄层加强材料，将经过印刷的薄膜粘合在该薄层加强材料的一面上。
这样，可保护薄层加强材料的经过开纤扩宽后的强化纤维面，并且可以使该薄层加强材料具有外观效果。
根据本发明，由于使薄层加强材料由将使每1000根的宽度大于等于1.3mm地开纤扩宽后的强化纤维单丝束浸渍在粘接性树脂而成的带状体构成，因此可提供薄的、轻型的且具有挠性特性、又具有高机械特性的加强材料。而且，通过将该薄层加强材料粘合在上述被加强基体上，不使上述被加强基体的重量或厚度或者挠性特性等特性发生大的变化、就可以提高该被加强基体的机械特性。
并且，在上述薄层加强材料的粘接性树脂是热熔树脂的情况下，可通过加热压接使该加强材料与被加强基体接合，因此，可大幅度简化接合操作。
并且，如果上述强化纤维是碳纤维，则可进一步提高薄层加强材料的机械特性，因此，可进一步提高被加强基体的机械特性。
并且，本发明的薄层加强材料由于将剥离型带粘合在该薄层加强材料的至少一面上，因此，可卷起该薄层加强材料进行保管，该保管方法简单，且可提高将上述薄层加强材料粘合在被加强基体上时的工作效率。
而且，如果将经过印刷的薄膜粘合在上述薄层加强材料的一面上，则可保护该加强材料的强化纤维，并可得到外观效果。
附图说明
图1是表示本发明的第一实施方式的单轴定向的经过开纤扩宽后的强化纤维，图(a)是其俯视图，图(b)是其剖视图。
图2是表示本发明的第一实施方式的单轴定向的加强带的图。
图3是表示本发明的第一实施方式的、在经过开纤扩宽后的强化纤维上接合带状的树脂、通过加压加热使该树脂浸渍的方法说明图。
图4是表示本发明的第一实施方式的单轴定向的经过开纤扩宽后的强化纤维的其它示例的图。
图5是表示在本发明的第一实施方式的加强带上粘合剥离型带的状态图。
图6是表示在本发明的第一实施方式的加强带上粘合经过印刷的薄膜的状态图。
图7是表示将本发明的第一实施方式的加强带粘在被加强基体上的状态示例的图，图(a)是表示向单轴方向粘合的示例，图(b)是表示向双轴方向粘合的示例，图(c)是表示只粘合在一部分上的示例。
图8是表示第一实施例的加强带的制造工序的图。
图9是表示在第一实施例的加强带的制造工序中粘合的剥离型薄膜的剖面模式图。
图10是表示在第一实施例的加强带的制造工序中得到的加强带的剖面模式图。
图11是通过图(a)至图(c)阶段性地表示将加强带依次粘合到第一实施例的帆船的帆上的状态的图。
具体实施方式
第一实施方式
就第一实施方式的薄层加强材料进行说明。
本薄层加强材料是由使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束通过粘接性树脂浸渍的带状体构成的薄层的加强材料。
并且，通过将本薄层加强材料粘合在作为加强对象的被加强基体上，可提高该被加强基体的机械特性。另外，这里的机械特性是指拉伸强度、撕裂强度。
粘合第一实施方式的薄层加强材料的被加强基体是轻型的、薄的且具有挠性的特性的基体，作为其典型例可举出帆船的帆。并且，上述被加强基体的其它例还有降落伞、帐篷、气球、建筑用膜材料或移动型的电、信息仪器的框体用罩布、包用罩布以及薄的管状杆等。
另外，作为被加强基体所具有的特性，可以举出具有轻型(单位面积的重量)、薄(厚度)的、以及挠性(单位宽度的弯曲刚性)的特性，它们最好分别小于等于0.2g/cm2、小于等于2mm、小于等于1.3Ncm2/cm(N：牛顿)。
以下就本发明的薄层加强材料(以下只称为“加强材料”或“加强带”)进行说明。
本发明的加强带是将事先使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束浸渍在粘接性树脂中而得到的。这样，既可保持加强效果，又可使该加强带的厚度形成得薄，也可减少重量增加的程度。
进行开纤扩宽的强化纤维的典型例有碳纤维。由于碳纤维的比弹性模量、比强度高，因此在可有效地提高加强带的机械特性方面尤其出色。强化纤维的其它例有玻璃纤维、对-芳香族聚酰胺纤维(パラ型アラミド繊維)、全芳香族聚酯纤维、超高分子量聚乙烯纤维、聚苯并唑等具有高力学物性的纤维。从轻型性、耐气候性、耐折叠性等方面来看，例如作为帆用基础材料的加强用纤维最好是超高分子量聚乙烯纤维。
强化纤维的开纤扩宽方法最好使用以下方法，即，使实际上非拈线的强化纤维束以松弛的状态移动，通过以实际上与其直交的方式向该下垂状的强化纤维束喷射经过整流的气流来进行开纤扩宽。如果增大下垂状态的垂度的大小或加大喷射的空气的流速，则扩宽的幅度增大。并且，如果加大所喷射的空气的流速，则可进一步增加扩宽的幅度。但是，如果过于扩宽，宽度方向的纤维的分布均匀性则降低，因此需要注意。另外，如上所述，为了实现既保持提高被加强基体的机械特性的效果、又使厚度变薄的本加强带的目的，需要将使每1000根的强化纤维单丝束扩宽到大于等于1.3mm。
如上所述，典型的经过开纤扩宽的强化纤维1的定向方式是图1所示的单轴定向。
使粘接性树脂(以下只称为“树脂”)11浸渍于该单轴定向的经过开纤扩宽的强化纤维1、得到图2所示的具有粘接性的薄层加强材料(以下称为“加强带”)10。
对浸渍在上述加强带10上的树脂11没有特别的限制，但由于含有高于限度的溶剂或水分的树脂在进行粘合时麻烦，因此，最好是无溶剂类的树脂。并且，尤其是浸渍树脂11后的加强带10需要充分的柔软性和耐折叠性的情况下，上述树脂11最好是热熔类的树脂。
而且，将上述经过开纤扩宽后的强化纤维1浸渍在树脂11中的方法可考虑以下方法，即，将树脂11涂在该经过开纤扩宽后的强化纤维1上，或如图3所示，将形成带状的树脂11与上述经过开纤扩宽后的强化纤维1的两面或一面接合后进行加压加热、浸渍的方法等。在本第一实施方式中，由于浸渍树脂11的强化纤维被开纤扩宽，因此具有树脂11容易浸渍到强化纤维的特征。但是，由于经过开纤扩宽后的强化纤维1很难保持其定向性，因此浸渍树脂时，如图4所示，为了使该经过开纤扩宽后的强化纤维的定向不移动，也可将多根强化纤维12设置在与该经过开纤扩宽后的强化纤维1的定向轴垂直的方向。
并且，作为浸渍在上述经过开纤扩宽后的强化纤维中的树脂量，虽然需要有向带状物上粘合时可确保充分的粘合强度的量，但为了保持上述加强带10的轻型性，最好使用尽量少的树脂，在实际使用中，最好少于等于80g/m2。
理想的制成后的加强带10是经过开纤扩宽后的强化纤维1浸渍在上述树脂11中，尤其是如图2所示，最好上述经过开纤扩宽后的强化纤维1全部都埋没在上述树脂11中。这样，可高度地发挥该经过开纤扩宽后的强化纤维的强化效率，而且向后述的被加强基体的粘合强度也有所提高，可缓和来自外部的横压负荷或冲击负荷等对强化纤维的破坏。另外，无需所有的经过开纤扩宽后的强化纤维都埋没在上述树脂中，上述树脂至少存在于该经过开纤扩宽后的强化纤维的两面，该纤维的大部分被上述树脂浸渍即可。
如图5所示，在这样制作的加强带10的两面或一面上预先粘合具有剥离型效果的剥离型带13。通过这样，在保管上述加强带10时，可以卷起的状态保管加强带10，并且，将上述加强带10粘合在上述被加强基体上时，可通畅地拉出加强带10进行粘合，因此也具有提高工作效率的效果。
并且，如图6所示，也可以事先在上述加强带10的一面粘合薄膜14。这样，薄膜14可保护加强带10的强化纤维，同时，如果在该薄膜14上进行印刷，也可提高外观效果。而且，如果使粘合在上述加强带10上的薄膜14具有剥离效果，则即使不将剥离带粘合在加强带10上、也可以通畅地拉出加强带10，在可提高工作效率的同时，可得到容易保管的效果。
并且，将如上所述地制作的加强带10粘合在被加强基体20上的情况下，将该加强带10沿着需要强化被加强基体20的机械特性的方向粘合。
在加强带10的强化纤维的定向是单轴定向的情况下，由于该加强带10的厚度薄、重量轻，因此，几乎不使上述被加强基体20的重量或厚度等特性发生变化，就可以提高该被加强基体20的机械特性。并且，由于将该加强带10粘合在需要强化的被加强基体20的机械特性的方向上即可，因此，也可得到增加需要强化的方向的自由度的效果。例如，可如图7(a)所示，将单轴定向的加强带10与一个方向平行地粘贴，也可如图7(b)所示，将该加强带10向着不同的方向重叠进行粘贴，或者如图7(c)所示，不将该加强带10粘贴在整个被加强基体20上，而是只粘贴一部分。并且，不仅可如图7(a)、(b)所示，将加强带10相互平行地粘贴，也可如图7(c)所示，形成曲线地粘贴。
另外，在相对上述被加强基体20进行双轴的强化或面的强化的情况下，使用上述的单轴定向的加强带10具有粘贴费事的问题。对于这种情况，可将经过开纤扩宽后的强化纤维单丝束事先设置成多轴、制作浸渍在树脂11中的带状体，将该多轴的加强带10粘合在被加强基体上。通过这样，只将多轴的加强带10原封不动地接合在被加强基体上，就可以高效率地且均匀地进行双轴的强化或面的强化、或者进行有目的的加强。上述的强化纤维单丝束的多轴设置的典型例有0度/90度的双轴、0度/+60度/-60度的三轴、(0度/+45度/-45度/90度)的四轴等，对此没有特别的限制。
如上所述，由于该第一实施方式的薄层加强材料是由使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束浸渍在粘接性树脂中的带状体形成的材料，因此，不用大幅度地改变被加强基体的厚度或重量、或者挠性等特性就可以付与该被加强基体高的机械特性。
并且，本发明的薄层加强材料由于是将剥离型带13粘合在至少一面上，因此，在保管薄层加强材料10时可用卷起该加强带10的状态进行保管，因此，其保管简便，同时，在将上述加强带10粘合在上述被加强基体上时，可将该加强带10通畅地拉出粘合，可提高粘合的工作效率。
而且，如果在本发明的薄层加强材料的一面上粘合事先经过印刷的薄膜，则可保护该加强带10的强化纤维，同时，也可提高外观效果。
另外，在上述说明中，对该薄层加强材料为带状体进行了说明，但在实际的带制造工序中，为了提高生产效率，最好制造具有与上述相同结构的宽幅的片状体的加强片，将其切成规定的宽度得到加强带。
第一实施例
1)加强带的制造
首先，将12K的300型的东丽碳纤维开纤扩宽到30mm。然后，将三十根该经过开纤扩宽后的强化纤维1无间隔且不重叠地合丝，向图8的制造装置供给。
然后，在该经过开纤扩宽后的强化纤维1的两面上设置从剥离型薄膜供给部2a、2b供给的、涂有热熔树脂薄层(每层20g/m2)的剥离型薄膜15，使该热熔树脂层与经过开纤扩宽后的强化纤维1接合。另外，图中的3是上下一对的辊、使上述碳纤维1和剥离型薄膜15通过这些辊之间。
图9是涂有树脂的剥离型薄膜15的剖面模式图。在图中，13是剥离型薄膜、11是热熔层，该剥离型薄膜13由涂有氟类树脂等的剥离层(面)13a和涂有剥离层的薄膜13b构成。
之后，使以剥离型薄膜、开纤强化纤维、剥离型薄膜的顺序依次设置的宽幅的带，一面用加热器4加热一面通过加压辊5a、5b之间，而且同样一面用加热器6加热一面通过加压辊7a、7b之间进行加压，使该被供给的碳纤维1浸渍在粘接性树脂中。
用卷绕机8来卷绕这样得到的经过一体化的宽幅的带16。此时用卷绕辊9卷绕粘合在宽幅带的两面的剥离型带13的一方。图10是此时得到的带的剖视图。
之后将带16切断成规定的宽度，得到在300mm宽度的单面上附有剥离型薄膜13的单轴定向的加强带。
2)向被加强基体20的粘合
被加强基体20是厚度为20μm的双向拉伸聚酯薄膜。该双向拉伸聚酯薄膜事先剪裁成型为宽约为7～8米、长约为20米的帆船的帆的形状。在该被加强基体20上，沿着在帆上需要强化的方向如图11(a)～(c)所示地依次粘合上述加强带10。然后，如图11(c)所示地在粘合在上述被加强基体20上的加强带10上层压接合网眼状的薄的织物，完成帆的制作。
这样得到的帆与现有的碳纤维强化的帆相比较，其厚度减少到大约53％(93μm)，同时，可使帆的重量减轻到大约30％。另外，在现有的碳纤维强化帆的情况下，在折叠帆时，在折叠的局部，碳纤维容易切断破损，而在该第一实施例的帆的情况下，由于将碳纤维进行开纤扩宽，形成超薄层，因此具有挠性、耐折叠性，可大幅度避免现有的难点。
本发明的薄层加强材料作为对薄的板状的物体、诸如帆船的帆、降落伞、各种气球或气囊等利用空气使其膨胀的物体、帐篷以及在建筑业中用于屋顶或天花板的拉伸结构等进行加强的材料非常有用。

Claims (11)

1.一种薄层加强材料，粘合在被加强基体上、强化该基体的机械特性，其特征在于，由使每1000根的宽度大于等于1.3mm地开纤扩宽的强化纤维单丝束浸渍在粘接性树脂而成的带状体构成。
2.如权利要求1所述的薄层加强材料，其特征在于，所述被加强基体是轻型的、薄的并具有挠性特性。
3.如权利要求2所述的薄层加强材料，其特征在于，所述被加强基体为片状体。
4.如权利要求1至3中任一项所述的薄层加强材料，其特征在于，所述粘接性树脂是热熔型树脂。
5.如权利要求1至4中任一项所述的薄层加强材料，其特征在于，将剥离型带至少粘合在该薄层加强材料的一面。
6.如权利要求1至4中任一项所述的薄层加强材料，其特征在于，所述强化纤维是碳纤维。
7.如权利要求1至4中任一项所述的薄层加强材料，其特征在于，所述强化纤维单丝束的层的该强化纤维沿单轴方向排列。
8.如权利要求7所述的薄层加强材料，其特征在于，以使该薄层加强材料的强化纤维的排列方向向着一个方向的方式，将该薄层加强材料粘在所述被加强基体上。
9.如权利要求7所述的薄层加强材料，其特征在于，以使该薄层加强材料的强化纤维的排列方向向着不同的方向的方式，将该薄层加强材料重叠粘在所述被加强基体上。
10.如权利要求1至4中任一项所述的薄层加强材料，其特征在于，所述被加强基体的主要构成成分是双向拉伸薄膜。
11.如权利要求1至4中任一项所述的薄层加强材料，其特征在于，将经过印刷的薄膜粘合在该薄层加强材料的一面上。
CNA2006800007112A 2005-08-25 2006-08-24 薄层加强材料 Pending CN101010177A (zh)

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