CN101181828B

CN101181828B - Intermediate material for forming FRP, and method for production thereof

Info

Publication number: CN101181828B
Application number: CN2007101809719A
Authority: CN
Inventors: 后藤和也; 古贺一城; 斋藤忠义; 伊藤彰浩; 高野恒男; 若林巧己
Original assignee: Mitsubishi Rayon Co Ltd
Current assignee: Mitsubishi Chemical Corp
Priority date: 2002-07-18
Filing date: 2003-07-18
Publication date: 2012-08-15
Anticipated expiration: 2023-07-18
Also published as: CN101181833A; CN101181827A; JP4177041B2; CN101181833B; CN101181827B; CN101181828A; CN101181829A; JP2004050574A

Abstract

A prepreg which comprises a reinforcing fiber, a reinforcing fiber base material in a sheet form having a reinforcing fiber, and a matrix resin, and has a portion not impregnated with the resin as a passage in evacuation, wherein the portion not impregnated with the resin is formed by a method comprising impregnating the reinforcing fiber base material in a sheet form with the matrix resin from one side thereof with a resin impregnation percentage of 35 to 95 %; a method comprising placing the matrix resin on both sides of the reinforcing fiber base material in a sheet form in such a way that the portion not impregnated with the resin is present in a continuous fashion inside the base material; or a method comprising forming a resin-impregnated part (an island part) having the matrix resin and a fiber part (a sea part) having no resin, on the surface of at least one side of the base material, in such a way that the resin covers 3 to 80 % of the surface and the island part accounts for 40 % or more of the weave texture of the base material. The above prepreg provides, even when it is formed by the use of the vacuum pressure alone, a FRP which is free of voids in the inside and pinholes on the surface thereof and exhibits excellent appearance.

Description

The fibre reinforced composites moulding is with intermediate materials and forming method thereof

The application is to be on July 18th, 2003 applying date of original application; Application number is 03816547.3, and denomination of invention is divided an application for the one Chinese patent application of " prepreg, FRP moulding are with the manufacturing approach of intermediate materials and manufacturing approach and fibre reinforced composites ".

Technical field

The present invention relates to the prepreg of the intermediate materials that moulding is used as FRP.

Background technology

Owing to have in light weight and intensity is high, rigidity is high, fibre reinforced composites (the following FRP that abbreviates as sometimes) are widely used in from physical culture and leisure purposes to industry purposes such as automobile, aircrafts.Particularly in recent years, because the price of carbon fiber descends gradually, it is more and more that gentlier and more the carbon fibre reinforced composite of high strength, higher rigidity (being designated hereinafter simply as CFRP) is used to the situation of industry purposes.

The CFRP that in the industry purposes, is used for the structure member of rail vehicle and airframe etc. typically uses the intermediate materials that is called as prepreg, to make with autoclave molding.This is because through utilizing autoclave moulding under high pressure, and discovery can reduce space in the moulding article, and can obtain the intensity of desired moulding article, and can suppress the surface pinholes generation, obtains the moulding article of appearance looks elegant.

In a single day but the price of autoclave equipment is very high, and obstacle is big when not only newly buying, and buys, because this autoclave has limited the size of moulding article, in fact can not make bigger moulding article.

To such problem, do not adopt the exploitation of autoclave, low-cost moulding to carry out energetically, as its representational forming method the baking molding (or also being called as vacuum bag moulding etc.) at vacuum, atmospheric pressure compacted under is only arranged.Because baking molding is not exerted pressure, even therefore be not that the such firm pressure resistant container of autoclave is also passable, as long as the stove that existence can heat up just can moulding.Even the so simple equipment of heat-insulating shield and storage heater also can moulding.But, owing to do not exert pressure, therefore easy remaining space in moulding article, it is compared with the moulding article that form with autoclave, has the low or such problem of generation pin hole of intensity.

In recent years also seeking the method that solves for such problem.The technology that relates to the material that is made up of resin bed and fortifying fibre layer is for example disclosed in WO 00/27632, even the moulding article that the space that also can obtain producing with baking molding is few, the surface is also very attractive in appearance.But, owing in forming process, flooded most of resin, can produce the part that does not have the thorough impregnation resin in this technology, thereby can produce inner space and surface pinholes according to condition of molding.In addition, very dry because the surface does not have resin, therefore also there is the problem on operability such as mould stickup difficulty.

Summary of the invention

Problem of the present invention is to provide a kind of intermediate materials; Its keep with the same operability of prepreg in the past in, even do not using autoclave, also can not produced the excellent FRP of internal voids and surface pinholes and outward appearance in only through the forming process of vacuum pressure.

Scheme one of the present invention relates to prepreg; It comprises fortifying fibre, has the sheet reinforcing-fiber substrate and the matrix resin of fortifying fibre; Said matrix resin is impregnated in the sheet reinforcing-fiber substrate and covers a side surface of sheet reinforcing-fiber substrate, and the matrix resin impregnation rate is more than or equal to 35%, smaller or equal to 95%.

Scheme two of the present invention relates to prepreg; It is the prepreg that is made up of sheet reinforcing-fiber substrate and matrix resin; Comprise fortifying fibre, have the sheet reinforcing-fiber substrate and the matrix resin of fortifying fibre; Said matrix resin is present on two surfaces of sheet reinforcing-fiber substrate, and is not continuous by the part of matrix resin dipping in the inside of sheet reinforcing-fiber substrate.

Scheme three of the present invention relates to prepreg; It comprises sheet reinforcing-fiber substrate and the matrix resin that is made up of reinforcement fabrics; At least one side surface forms the island shape that is made up of the pars fibrosa (extra large portion) that does not have matrix resin on resin dipping part (island portion) that has matrix resin on the surface and the surface; The surface coverage of matrix resin that forms the surface of island shape be more than or equal to 3%, smaller or equal to 80%, and the island portion that representes with following formula (1) knit the hole occupation rate more than or equal to 40%.

Hole occupation rate (%)=(T/Y) * 100 (1) is knitted by island portion

(T: cover and to knit island portion number, the Y in hole: be positioned at the face side that forms the island shape reinforcement fabrics knit number of perforations)

In addition; Scheme four of the present invention relates to the FRP moulding and uses intermediate materials; It comprises the prepreg with fortifying fibre and matrix resin and is arranged on the base material that does not flood compositions of thermosetting resin in fact at least one side surface of prepreg, the thickness of above-mentioned prepreg (A), with the ratio (B)/(A) of the thickness (B) of base material be more than or equal to 0.1, smaller or equal to 2.5.

According to above-mentioned formation, can keep with the same operability of prepreg in the past in, even do not adopting autoclave, also can access the FRP that does not produce inner space and surface pinholes and outward appearance excellence in only through the forming process of vacuum pressure.

Description of drawings

Fig. 1 is at the cross section ideograph that is employed in the prepreg that the thin slice that is arranged with fiber on the direction cuts as the direction perpendicular to fiber of the prepreg of sheet reinforcing-fiber substrate;

Fig. 2 is the cross section ideograph at the prepreg that adopts plain to cut as the direction perpendicular to warp of the prepreg of sheet reinforcing-fiber substrate;

Fig. 3 is the ideograph of an example of the prepreg of expression scheme two of the present invention;

Fig. 4 is the comparative example of the ideograph of the prepreg when face is supplied with matrix resin;

Fig. 5 is that expression is from two faces supply matrix resins, still not by the comparative example of the ideograph of the part of matrix resin dipping and discrete example;

Fig. 6 is the surface modes figure of the prepreg of scheme three of the present invention;

Fig. 7 is the comparative example of the surface modes figure that knits the low prepreg of hole occupation rate of island portion;

Fig. 8 is example and the figure that tries to achieve the method for its Tg from this chart of the chart of the expression dynamic stiffiness rate of measuring matrix resin.

The specific embodiment

Describe about formation of the present invention.

Embodiment one of the present invention relates to prepreg; It is impregnation matrix resin and the prepreg that forms in the sheet reinforcing-fiber substrate that is made up of fortifying fibre; It is characterized in that; Only the sheet reinforcing-fiber substrate face is covered with whole ground of resin, and the resin impregnation rate is more than or equal to 35%, smaller or equal to 95%.Fiber as the sheet reinforcing-fiber substrate that prepreg adopted that is used for embodiment one; Not special restriction; Can enumerate carbon fiber, glass fibre, aramid fibre, high-strength polyethylene fiber, boron fibre, steel wire fibre etc.; But consider from the mechanical properties of the performance of the FRP that obtains, particularly in light weight, high strength and high rigidity, preferably use carbon fiber.

In addition; Be used for the not special restriction of form of sheet reinforcing-fiber substrate of the prepreg of embodiment one; Can enumerate: with plain, twills, satin fabric or fibre bundle in a direction or translation-angle lamination, sew up resulting sutural lamina or nonwoven, shim-like thing as no crimped fibre fabric (NCF) with the mode of not untiing this lamination state then; And further draw neat folk prescription to material etc. in a direction reinforcing fiber bundles, preferably use good fabric of operability or sutural lamina.

In addition; As the matrix resin of the prepreg that is used for embodiment one, also not special restriction can be used thermosetting resin or thermoplastic resin; But, preferably use thermosetting resin from considering as operability such as the viscosity of prepreg and drapability, mouldability.As thermosetting resin; Can enumerate epoxy resin, phenolic resins, vinylester resin, unsaturated polyester resin, bimaleimide resin, bismaleimide-triazine resin, cyanate ester resin, benzoxazine colophony etc.; But consider from operability, solidfied material rerum natura; Preferred epoxy resin, bimaleimide resin, bismaleimide-triazine resin, the cyanate ester resin of using wherein especially preferably uses epoxy resin.

For the prepreg of embodiment one, whole ground of face covering resin, the resin impregnation rate must be more than or equal to 35%, smaller or equal to 95%.Do not use autoclave, during only with the vacuum pressure moulding, guarantee that exhaust channel is important, this point is also pointed out in prior art so far.Here, so-called exhaust channel is the part that resin does not have dipping in prepreg, is the part that becomes air flue.But if exhaust channel is excessive, then moulding final vacuum path can be residual, becomes the reason of internal voids and surface pinholes on the contrary.The inventor studies the suitable size of the exhaust channel in the prepreg, and the result finds that the resin impregnation rate when certain proper range, can guarantee sufficient exhaust channel, and the dipping of the resin when moulding is also abundant simultaneously, thereby accomplishes the present invention.

In conjunction with figure this resin impregnation rate is elaborated.Fig. 1 is the cross section ideograph that is arranged with the prepreg 10 that the direction perpendicular to fiber of the reinforcing-fiber substrate of fiber cuts in one direction.Matrix resin is supplied with in below by Fig. 1, and matrix resin 1 quilt is impregnated in the sheet reinforcing-fiber substrate towards the top.In Fig. 1, represented to flood the part of matrix resin 1 with oblique line.In addition, in Fig. 1 by below supply with matrix resin, but among the present invention, also can supply with matrix resin from the top, impregnation matrix resin towards the below.To sheet reinforcing-fiber substrate fabric width direction carry out cross-section more than or equal to 80%, obtain the peak (obtaining minimum point when supplying with resin) that resin arrives by the top.In Fig. 1, the A point is the peak of resin.The average thickness of sheet reinforcing-fiber substrate is made as t ₁, the distance of ordering to A from the lower end of reinforcing-fiber substrate is made as a, then impregnation rate is represented with following formula (3).

Resin impregnation rate=a/t ₁* 100 (%) (3)

In addition, the average thickness t of sheet reinforcing-fiber substrate ₁Obtain as follows.With the thickness of the 10a bottom of the sectional view that connects prepreg 10 and the line of 10b topmost (with this as relative contour) distance as this flat substrates, measure any thickness at 10, average the average thickness t of back as this sheet reinforcing-fiber substrate ₁In addition, for the situation of the sheet reinforcing-fiber substrate that is arranged with fiber in one direction, the outline of base material is almost consistent with relative contour.

When asking for the peak of matrix resin 1 arrival; See from observing easily perpendicular to the cross section of fortifying fibre; From but suitable; Therefore be not the fiber arranged in one direction sheet reinforcing-fiber substrate as Fig. 1, for the multiaxis of all directions lamination to the situation of sutural lamina etc., also can get cross-section photograph and observe from the angle bat of easy observation.

In addition, the sharp keen cutting machine as scissors is used in cutting, does not carry out any drawing and once cuts into.Multiple is advisable with about 50～100 times.

Then, example when the sheet reinforcing-fiber substrate is fabric 20 is described.Resin impregnation rate when expression is used plain weave as the sheet reinforcing-fiber substrate among Fig. 2 ask method.Under the situation of fabric, owing to matrix resin 1 moves along aperture portion 21, therefore to be advisable through the cross-section of aperture portion 21.For the reinforcing-fiber substrate that is arranged with fiber in one direction, obtain the peak B that matrix resin 1 arrives like the said cross section of Fig. 1 from Fig. 2.Setting from the distance of the lower end 20a to B of reinforcing-fiber substrate point be b, the line distance that connects the 20a bottom of this sheet reinforcing-fiber substrate and 20b topmost is t as thickness, the average thickness of sheet reinforcing-fiber substrate ₂, then the resin impregnation rate can use formula (4) to obtain.In addition, average thickness t ₂With the method identical method mensuration illustrated with the reinforcing-fiber substrate situation that is arranged with fiber in one direction, but under the fabric situation, the outline and the relative contour of sheet reinforcing-fiber substrate inconsistent (with reference to Fig. 2).

Resin impregnation rate=b/t ₂* 100 (%) (4)

Resin impregnation rate in the prepreg of embodiment one be preferably more than equal 35%, smaller or equal to 95%.The resin impregnation rate was less than 35% o'clock, and resin can complete filling flood part during moulding, thereby residual after moulding have internal voids and a surface pinholes.The resin impregnation rate was difficult to residual internal voids and surface pinholes more than or equal to 40% o'clock after moulding, thereby preferred, was preferably greater than especially to equal 50%.In addition, the resin impregnation rate surpasses at 95% o'clock, can not guarantee exhaust channel, and it also can residually have internal voids and surface pinholes.The resin impregnation rate was guaranteed exhaust channel more easily smaller or equal to 90% o'clock, thereby preferred, the resin impregnation rate was more preferably smaller or equal to 80% o'clock.

Prepreg one face of the present invention must whole ground covering resin.Owing to prepreg sticks on mould or which floor prepreg lamination is used, therefore suitable viscosity must be arranged.Because therefore whole ground of prepreg one face of the present invention covering resin has suitable viscosity, operability is also excellent.

The weight per unit area of the sheet reinforcing-fiber substrate in the prepreg of embodiment one is preferably more than and equals 400g/m ²The prepreg of embodiment one has exhaust channel; And; Resin can move to the sheet reinforcing-fiber substrate everywhere in forming process simultaneously; Thereby thorough impregnation and do not produce the internal voids and the surface pinholes of moulding article, therefore being suitable for the sheet reinforcing-fiber substrate has the to a certain degree situation of thickness.If with weight per unit area, be fit to more than or equal to 400g/m ²The sheet reinforcing-fiber substrate.If more than or equal to 600g/m ²Then more preferably, be preferably greater than especially and equal 700g/m ²

In addition, the thickness of the sheet reinforcing-fiber substrate in the prepreg of embodiment one is preferably more than and equals 200 μ m.For the prepreg of embodiment one, even the situation of the flowability difference of matrix resin only under atmospheric pressure just can obtain the good moulding article that inside does not have the space.Therefore, also can obtain good moulding article even the sheet reinforcing-fiber substrate is thick, opposite thick situation effect of the present invention can be by significantly performance.Particularly the thickness of sheet reinforcing-fiber substrate is more remarkable more than or equal to the situation of 300 μ m.Thickness can be by the ratio of the quality of the unit are of the density of the fortifying fibre that constitutes and sheet reinforcing-fiber substrate and is obtained.

When the matrix resin of the prepreg of embodiment one is thermosetting resin, preferably in compositions of thermosetting resin, contain the thermoplastic resin that is not dissolved in this compositions of thermosetting resin.This thermoplastic resin is preferably short fiber, and its length is preferably 1～50mm.And its fiber number is preferably smaller or equal to 300 spies.

During the prepreg of lamination moulding embodiment one; In the compositions of thermosetting resin in forming process; The fortifying fibre that the short fiber that is formed by thermoplastic resin is configured the sheet reinforcing-fiber substrate filters, and be configured in each sheet reinforcing-fiber substrate of lamination the surface, be the interlayer of laminate.Can significantly improve interlaminar strength like this, and give play to excellent interlayer reinforced effects.

In order to have given play to this interlayer reinforced effects effectively, thermoplastic resin is preferably fibrous.Replace short fiber and when adopting other shape for example microgranular; Thermosetting resin can not more effectively be filtered by the sheet reinforcing-fiber substrate in forming process; Thermoplastic resin can move to inside with thermosetting resin when impregnated in the sheet reinforcing-fiber substrate, therefore sometimes effectively between enhancement layer.

Therefore, thermoplastic resin is preferably the short fiber shape.And then preferably its length is 1～50mm.The length of short fiber is during less than 1mm, and to get into the sheet reinforcing-fiber substrate equally sometimes inner with the situation of particulate, can not improve the anti-fissility of interlayer effectively, thus itself and not preferred.Thereby, consider from the size that must have to a certain degree, length during more than or equal to 3mm for more preferably.On the contrary, length is during greater than 50mm, the significantly difficulty because long and preparation compositions of thermosetting resin becomes, and make it evenly be dispersed to the difficulty that also becomes in the thermosetting resin, and therefore, consequently interlayer strengthens and becomes inhomogeneous, thereby and not preferred.Length during smaller or equal to 30mm for more preferably.

In addition, when thermoplastic resin was short fiber, its fiber number was preferably smaller or equal to 300 spies.As the form of the short fiber that forms by thermoplastic resin, both can be the monofilament that forms by single ultimate fibre, also can be the multifilament that forms by some ultimate fibres.If fiber number is greater than 300 spies; The layer thickening that the short fiber of then assembling at interlayer forms, short fiber can disturb the fortifying fibre of sheet reinforcing-fiber substrate, to knit the hole crooked thereby fortifying fibre might produce; Therefore can reduce the mechanical strength of the composite that moulding obtains, so also not preferred.Fiber number is more preferably less than and equals 100 spies, especially preferably smaller or equal to 50 spies.Do not limit its thin degree especially for fiber number, so long as just can obtain effect of sufficient more than or equal to 1 spy.

As thermoplastic resin, can enumerate and for example gather aromatic polyamides, polyester, polyacetals, Merlon, polyphenylene oxide, polyphenylene sulfide, polyacrylate, polyimides, PEI, polysulfones, polyamide, polyamidoimide, polyether-ether-ketone etc.In addition, be not only thermoplastic resin, also can use elastomer aptly.As elastomer, can enumerate natural rubbers such as synthetic rubber such as butyl rubber, isoprene rubber, acrylonitrile-butadiene rubber, silicon rubber and latex.

The content of thermoplastic resin in thermosetting resin is 1～100 mass parts with respect to 100 mass parts compositions of thermosetting resin preferably.Therefore and not preferred the content of thermoplastic resin is during less than 1 mass parts, and the raising effect of the anti-fissility of interlayer of FRP can be insufficient.More preferably more than or equal to 5 mass parts, be preferably more than especially and equal 10 mass parts.On the contrary; During greater than 100 mass parts, because the ratio of thermoplastic resin is too much, matrix resin becomes many to the ratio of the relative sheet reinforcing-fiber substrate of dipping property variation, matrix resin of sheet reinforcing-fiber substrate; Thereby the mechanical strength of FRP descends, and is therefore also not preferred.

As the not special restriction of the method for the prepreg of making embodiment one; Preferably a side from the sheet reinforcing-fiber substrate that is made up of fortifying fibre utilizes the heat fusing method to supply with resin, heats and pressurize to make resin move near the of opposite face and the method for manufacturing prepreg.At this moment, through regulating amount of movement, the moving state that heating-up temperature, moulding pressure are adjusted resin, with the resin impregnation rate be adjusted to more than or equal to 35%, smaller or equal to 95%.So-called heat fusing method is that the viscosity that does not contain solvent, reduces resin through the temperature that improves resin makes resin be impregnated into the manufacturing approach of the prepreg in the base material.As method, consider the preferred two-sided embrane method of supplying with resin from the positive and negative of sheet reinforcing-fiber substrate of using from dipping face or the like usually with heat fusing manufactured prepreg.But in embodiment one, because a face of prepreg must not flood for forming exhaust channel, therefore two-sided embrane method is not the method that is preferably the prepreg of making embodiment one.As previously mentioned, preferably supply with the single face embrane method of resin from a face of sheet reinforcing-fiber substrate.

When the matrix resin of the prepreg of embodiment one be compositions of thermosetting resin, when in this compositions of thermosetting resin, containing undissolved thermoplastic resin; Preferably, make it be impregnated into the method in the sheet reinforcing-fiber substrate its filmization then the stage mixed thermoplastic resin who mixes, prepares compositions of thermosetting resin.

Embodiment two of the present invention relates to prepreg; It is the prepreg that is made up of sheet reinforcing-fiber substrate and matrix resin; Matrix resin is present on two surfaces of sheet reinforcing-fiber substrate, and is not continuous by the part of matrix resin dipping in the inside of sheet reinforcing-fiber substrate.

Fortifying fibre as the sheet reinforcing-fiber substrate of the prepreg that is configured for embodiment two; Not special restriction; Can enumerate carbon fiber, graphite fibre, aramid fibre, silicon carbide fibre, alumina fibre, boron fibre, h, gather penylene benzo-dioxazole fiber, glass fibre etc.; In addition, these fibers can use separately, also can make up several kinds of uses.Wherein, because carbon fiber is excellent aspect specific strength, non-resilient rate, and glass fibre is excellent aspect cost performance, therefore preferred these fortifying fibres that use.

The also not special restriction of the form of the sheet reinforcing-fiber substrate of using in the prepreg of embodiment two; Can be a direction draw neat folk prescription to material, fabric, braid, composition, be sewn to the composite fiber fabric of lamination on a direction or a plurality of direction and any one of the sutural lamina that obtains, the gasket material of processing by short fiber or the such form of nonwoven; But for the excellent in stability of sheet reinforcing-fiber substrate itself, FRP moulding of the present invention good with the operability of intermediate materials, preferably with fabric, sutural lamina, pad or nonwoven form as the sheet reinforcing-fiber substrate.

In the prepreg of embodiment two, there is not the necessary continued presence of part of impregnation matrix resin in sheet reinforcing-fiber substrate inside.The existence of this exhaust channel in embodiment two, do not have impregnated part to become exhaust channel, owing to can not produce internal voids and surface pinholes among the FRP after the moulding.But, if this exhaust channel is blocked by matrix resin, very difficult discharge of air of then being surrounded by matrix resin, thus can become the reason that produces space and pin hole etc.

Whether the part of being flooded by matrix resin in sheet reinforcing-fiber substrate inside does not exist according to following operation is continuously judged.At first, the length direction of corresponding prepreg cuts into the right angle.During cutting, use once cuttings such as NT cutting machine.Therefore and not preferred if repeatedly describe then can confound cut surface.The width of corresponding cut surface, each cutting of two ends goes 10%.To remaining width, the part to 80% is carried out complete observation to confirm in inside being not continuous by the part of matrix resin dipping.At this moment, preferably use magnifying glass etc. to observe.

Fig. 3 is by the matrix resin impregnate layer of having flooded matrix resin 1 31 and the matrix resin prepreg 30 of the sheet reinforcing-fiber substrate that constitutes of impregnate layer 32 not.It is when having flooded matrix resin 1 matrix resin not impregnate layer 32 are continuous examples.

On the other hand, Fig. 5 is by the matrix resin impregnate layer of having flooded matrix resin 1 51 and the matrix resin prepreg 50 of the sheet reinforcing-fiber substrate that constitutes of impregnate layer 52 not.It is when having flooded matrix resin 1 matrix resin not impregnate layer 52 are discontinuous examples.

As the matrix resin of the prepreg that is used for embodiment two, not special restriction can not used thermosetting resin or thermoplastic resin, but from considering as operability, mouldabilities such as the viscosity of prepreg or drapability, preferably uses thermosetting resin.As thermosetting resin; Can enumerate epoxy resin, phenolic resins, vinylester resin, unsaturated polyester resin, bimaleimide resin, bismaleimide-triazine resin, cyanate ester resin, benzoxazine colophony etc.; But consider from the rerum natura of operability, solidfied material; Preferred epoxy resin, bimaleimide resin, bismaleimide-triazine resin, the cyanate ester resin of using wherein, especially preferably uses epoxy resin.

The weight per unit area of the sheet reinforcing-fiber substrate in the prepreg of embodiment two is preferably more than and equals 400g/m ²The prepreg of embodiment two has exhaust channel; And; Simultaneously resin can move to reinforcing-fiber substrate everywhere in forming process, thus thorough impregnation and the internal voids and the surface pinholes of moulding article do not take place, so be suitable for the sheet reinforcing-fiber substrate and have certain thickness situation.If with weight per unit area, be fit to more than or equal to 200g/m ²The sheet reinforcing-fiber substrate.If more than or equal to 600g/m ²Then more preferably, be preferably greater than especially and equal 700g/m ²

In addition, as the thickness of the sheet reinforcing-fiber substrate in the prepreg of embodiment two, be preferably more than and equal 200 μ m.For the prepreg of embodiment two,, only under atmospheric pressure just can obtain the good moulding article that inside does not have the space even during the flowability difference of matrix resin.Therefore, even the sheet reinforcing-fiber substrate is thick, also can obtain good moulding article, on the contrary, thick situation is performance effect of the present invention significantly.Particularly the thickness of sheet reinforcing-fiber substrate is more remarkable during more than or equal to 300 μ m.Thickness can be by the ratio of the quality of the unit are of the density of the fortifying fibre that constitutes and sheet reinforcing-fiber substrate and is obtained.

When the matrix resin of the prepreg of embodiment two is compositions of thermosetting resin, preferably in compositions of thermosetting resin, contain the thermoplastic resin that is not dissolved in this compositions of thermosetting resin.This thermoplastic resin is preferably short fiber, and its length is preferably 1～50mm.And its fiber number is preferably smaller or equal to 300 spies.

During the prepreg of lamination moulding embodiment two; In the forming process in compositions of thermosetting resin; The fortifying fibre that the short fiber that is formed by thermoplastic resin is configured the sheet reinforcing-fiber substrate filters, and be configured in each sheet reinforcing-fiber substrate of lamination the surface, be the interlayer of laminate.Interlaminar strength is significantly improved, given play to excellent interlayer reinforced effects.

In order to bring into play this interlayer reinforced effects effectively, thermoplastic resin is preferably fibrous.Replace short fiber and when adopting other shape for example microgranular; Thermosetting resin can not filtered by the sheet reinforcing-fiber substrate in forming process effectively; Thermoplastic resin meeting and thermosetting resin move to inside together in the time of in being impregnated into the sheet reinforcing-fiber substrate, therefore sometimes effectively between enhancement layer.

Therefore, be preferably the short fiber that forms by thermoplastic resin.And then preferably its length is 1～50mm.The length of short fiber is during less than 1mm, and to get into the sheet reinforcing-fiber substrate equally sometimes inner with the situation of particulate, thereby can not improve the anti-fissility of interlayer effectively, thus itself and not preferred.Thereby, consider from the size that must have to a certain degree, length during more than or equal to 3mm for more preferably.On the contrary, length is during greater than 50mm, the significantly difficulty because long and preparation compositions of thermosetting resin becomes, and make it evenly be dispersed to the difficulty that also becomes in the thermosetting resin, and therefore, consequently interlayer strengthens and becomes inhomogeneous, thereby and not preferred.Length during smaller or equal to 30mm for more preferably.

When the matrix resin that uses in the prepreg of embodiment two was compositions of thermosetting resin, preferably this hardening resin composition solidified under 90 ℃, 2 hours condition, more preferably under 80 ℃, 2 hours condition, solidified.Prepreg for embodiment two; Even during as the flowability difference of the hardening resin composition of matrix resin; Only under atmospheric pressure just can obtain the good moulding article that inside does not have the space, therefore, compositions of thermosetting resin is suitable for being cured in lower temperature.

On the other hand, in general prepreg operability at room temperature must be good.Key factor as operability is viscosity (the sticking situation that twines) and drapability (flexibility), in order to adjust viscosity and drapability, and must be as the hardening resin composition of matrix resin at certain range of viscosities.If the viscosity of thermally curable resin composition is low excessively, then viscosity is crossed by force, very difficulty is operated; In addition, if viscosity is too high, then viscosity is weak excessively, becoming does not have drapability, and this also can be difficult to operation.Like this, in order to bring into play the good operability as prepreg, thermally curable resin composition must be at suitable range of viscosities.Therefore; Under lower temperature, solidify and be meant that correspondingly compositions of thermosetting resin is cured at higher range of viscosities; Thereby, even the thermally curable resin composition of suitable prepreg as the mobile embodiment two that poorly also can obtain good moulding article.

Whether compositions of thermosetting resin solidifies as follows under 90 ℃, 2 hours condition is judged.Compositions of thermosetting resin is only being arranged or compositions of thermosetting resin is being impregnated into the state in the sheet reinforcing-fiber substrate, the actual baking oven that uses was at 90 ℃, 2 hours condition compacted under.If the solidfied material that obtains obviously solidifies in appearance, then be regarded as under 90 ℃, 2 hours condition, solidifying.Whether under 80 ℃, 2 hours condition, solidify in addition, also is same.During the difficult judgment of whether solidifying, measure the Tg of formed body, solidify if this Tg more than or equal to 30 ℃, then is judged as.

Usually when intermediate materials is used in FRP moulding such as making prepreg, the method that the compositions of thermosetting resin of coating supply thinly on processing release paper or polyolefin film etc. is flooded is arranged as the method to sheet reinforcing-fiber substrate impregnation matrix resin on reinforcing-fiber substrate.Wherein, only roughly be divided into from a side of reinforcing-fiber substrate and supply with and the single face embrane method of dipping and supply with and the two-sided embrane method of dipping from both sides.In embodiment two, the method for very preferably supplying with two-sided embrane method.This be because, the hardening resin composition that is cured at low temperature, the i.e. smaller compositions of thermosetting resin of flowability are used in supposition in embodiment two.Fig. 3 and Fig. 4 represent respectively with two-sided embrane method and the ideograph of single face embrane method when the sheet reinforcing-fiber substrate of same thickness is supplied with the same amount resin.

Fig. 3 is to have matrix resin impregnate layer 31 and matrix resin not mode and the prepreg 30 that constitutes of impregnate layer 32 from the both sides impregnation matrix resin 1 of sheet reinforcing-fiber substrate the time.

Fig. 4 is to have matrix resin impregnate layer 41 and matrix resin not mode and the prepreg 40 that constitutes of impregnate layer 42 from a side impregnation matrix resin 1 of sheet reinforcing-fiber substrate the time.

Like Fig. 3 and shown in Figure 4, when making the prepreg of embodiment two respectively with single face embrane method and two-sided embrane method, with the prepreg of double-side membrane manufactured with compare with the prepreg of single face embrane method manufacturing, there is the tendency that broadens in impregnate layer 42.Therefore, use two-sided embrane method to compare,, therefore before solidifying fully, fill exhaust channel easily for the amount of movement of filling the hardening resin composition in the necessary forming process of exhaust channel can be accomplished less with using the single face embrane method, thus preferred.

In addition,, preferably do not heat, at room temperature paste, but when the viscosity of the matrix resin under the room temperature is too high, can heat a little yet to improve flowability when the sheet reinforcing-fiber substrate is supplied with matrix resin.But, even such situation is inner continuous not by the part of matrix resin dipping in order to keep as hereinafter described, preferably smaller or equal to 40 ℃, more preferably heating smaller or equal to 30 ℃.

The matrix resin of the prepreg of embodiment two is compositions of thermosetting resin; When containing the thermoplastic resin that is not dissolved in this thermosetting resin; Preferably, make it be impregnated into the method in the sheet reinforcing-fiber substrate its filmization then the stage mixed thermoplastic resin who mixes, prepares compositions of thermosetting resin.

The prepreg of embodiment three of the present invention is impregnation matrix resin and prepregs of forming in reinforcement fabrics; At least one side surface forms the island shape that is made up of the pars fibrosa (extra large portion) that does not have matrix resin on resin dipping part (island portion) that has matrix resin on the surface and the surface; The surface coverage of matrix resin that forms the surface of island shape be more than or equal to 3%, smaller or equal to 80%, and the island portion that representes with following formula (5) knit the hole occupation rate more than or equal to 40%.

Hole occupation rate (%)=(T/Y) * 100 (5) is knitted by island portion

The prepreg of embodiment three is impregnation matrix resin and prepregs of forming in reinforcement fabrics.As the fortifying fibre that forms fabric; Can use carbon fiber, glass fibre, aramid fibre, boron fibre, metallic fiber, gather penylene benzo-dioxazole fiber, high-strength polyethylene fiber etc.; Wherein, Mechanical property after the carbon fiber moulding is good and in light weight, therefore especially preferably uses.In addition, the form of fabric can be enumerated plain, twills, satin fabric, be sewn to that a direction is drawn neat long fibre and the sutural lamina, the cord fabric that form.Further, also it doesn't matter to use the warp fiber different with parallel.

In addition, for the reinforcement fabrics of using in the embodiment three, preferably use its fiber weight per unit area smaller or equal to 1500g/m ²Reinforcement fabrics.Like the fruit fiber weight per unit area greater than 1500g/m ², then the density of fortifying fibre is too high, is difficult to obtain the excellent moulding article of mechanical properties.More preferably smaller or equal to 1000g/m ²About the not special restriction of the lower limit of fiber weight per unit area, equal 50g/m but be preferably more than ², more preferably more than or equal to 75g/m ²If less than 50g/m ², in the time of obtaining large-scale FRP, just must increase the number of the prepreg of lamination, therefore might increase expense.

The not special restriction of kind of matrix resin of the prepreg of embodiment three can be used for, the thermosetting resin and the thermoplastic resins such as acrylic resin and polyether-ether-ketone such as bismaleimide-triazine resin of epoxy resin, mylar, vinylester resin, phenolic resins, maleimide resin, polyimide resin, cyanate and bimaleimide resin combination can be enumerated.Particularly matrix resin is relevant with the intensity raising of the FRP that obtains, and is therefore preferred, wherein because the adhibit quality of epoxy resin and fortifying fibre is excellent, and the mechanical properties of the FRP that obtains is improved, so can enumerate it as suitable especially example.

As epoxy resin; For example can be: as bisphenol A type epoxy resin, bisphenol f type epoxy resin, bisphenol-s epoxy resin, biphenyl type epoxy resin, naphthalene type epoxy resin, dicyclopentadiene type epoxy resin, the fluorenes type epoxy resin of two functional resins or use the modified resin of these resins with following resin as matrix resin; As the phenol thermoplastic phenolic type epoxy resin of trifunctional or the multi-functional epoxy resin more than the trifunctional, cresols type epoxy resin, as the glycidyl amine type epoxy resin Fourth Ring oxygen propyl group MDA, three glycidyl amino-phenols, the Fourth Ring oxygen propyl group amine, as four (glycidyl hydroxyphenyl) ethane and three (glycidyl hydroxyl methane) the glycidyl ether type epoxy or use the modified resin of these resins, and these resins are made up more than a kind or a kind at least.

In addition; In these composition epoxy resins, can cooperate curing agent such as diphenyl-methane, diamino diphenyl sulfone, fatty amine, imdazole derivatives, dicyano diamides, TMG, thiourea addition amine, carboxylic acid hydrazides, carboxylic acid amide, polyphenolic substance, polymercaptan, boron trifluoride ethylamine complex compound, perhaps also can in resin combination, cooperate the material that can make epoxy resin and the said curing agent generation of part pre-reaction.And then, if also cooperate curing catalysts such as 3-(3,4-dichlorophenyl)-1,1-dimethyl urea, phenyl dimethyl urea, then can shorten hardening time, can shorten molding time.

Further, when the matrix resin in the embodiment three was compositions of thermosetting resin, the preferred MV minium viscosity of this compositions of thermosetting resin was smaller or equal to 1000 pools.If use MV minium viscosity greater than the such high compositions of thermosetting resin of viscosity of 1000 pools, the flowability of compositions of thermosetting resin can variation.In the prepreg of embodiment three; Filled thermoset resin combination in the exhaust channel that plays a role gradually during moulding; Flowability as crossing compositions of thermosetting resin is poor, and moulding just is through with before end-of-fill, and remaining exhaust channel might become the space.As its solution, must increase the weight per unit area of resin because expense and and not preferred.Therefore, what MV minium viscosity was little is advisable, and is preferably especially smaller or equal to 500 pools.

In addition, the MV minium viscosity in the so-called embodiment three is meant that from room temperature the viscosity of thermosetting resin becomes the viscosity of minimum point during with 5 ℃/minute programming rate intensification thermosetting resin.The MV minium viscosity of compositions of thermosetting resin can be obtained with the dynamic viscoelastic of the compositions of thermosetting resin 5 ℃ of/minute intensifications through measuring near room temperature.

The prepreg of embodiment three; It is characterized in that; At least one side surface forms the island shape that is made up of the pars fibrosa (extra large portion) that does not have matrix resin on the resin dipping part (island portion) that has matrix resin on the surface and the surface, and the surface coverage of the matrix resin on the surface of formation island shape is more than or equal to 3%, smaller or equal to 80%.

At first, use description of drawings island shape structure.Fig. 6 forms the ideograph of the mode of island shape to the prepreg of the formed embodiment three of reinforcement fabrics impregnating resin composition of plain weave with a face.Surface with the fabric 60 of fortifying fibre braiding is made up of island portion 61 and extra large portion 62.In the island portion 61, suppose to separately exist in knit in the hole 64 for the 61a of island portion, be connected with adjacent island portion be the 61b of island portion.Like this, intersperse from the teeth outwards through island portion 61, sea portion 62 constitutes exhaust channel when the prepreg moulding.Suppose adjacency knit hole 64 be spaced apart the distance 63.

In the prepreg of embodiment three, the surface coverage that forms the surface of island shape must be more than or equal to 3%, smaller or equal to 80%.Here, so-called surface coverage is meant the ratio of surface area on surface of formation island shape of the relative prepreg of area of island portion 61.

If surface coverage is less than 3%, particularly since the viscosity on the surface of the formation island shape of prepreg excessively a little less than, so operability variation of prepreg.On the other hand, if greater than 80%,, therefore become the reason that produces space or pin hole because the exhaust channel of prepreg almost stops up.If consider the balance of the size of viscosity and exhaust channel, surface coverage is preferably more than and equals 5%, is preferably smaller or equal to 60% especially.

In addition, in the prepreg of embodiment three, form the island shape the surface knit the hole occupation rate for more than or equal to 40% with the island portion 61 of following formula (6) expression.

Hole occupation rate (%)=(T/Y) * 100 (6) is knitted by island portion

Here, T be cover island portion number, the Y knit the hole be positioned at the face side that forms the island shape reinforcement fabrics knit number of perforations.In addition, the hole 64 of knitting in the so-called embodiment three is meant the intersection point through thread end and parallel end.

For example in Fig. 6, the island portion 61 of knitting hole 64 that covers reinforcement fabrics is 11, i.e. T=11.On the other hand, in the figure, because Y=15, thereby the hole occupation rate of knitting of the island portion of this moment is (11/15) * 100=73%.

On the other hand, Fig. 7 is the figure on surface of the fabric 60 of the many situation of the number of the expression island 61b of portion.For the island portion 61 among Fig. 7 knit the hole occupation rate because therefore T=3, Y=15 be (3/15) * 100=20%.

In addition, when the number T of island portion in hole was knitted in the mensuration covering, the resin dipping part 65 of knitting the hole that does not cover reinforcement fabrics was not included in this number among the present invention.

Like this, be more than or equal to 3%, smaller or equal to 80% o'clock at the surface coverage of resin, if island portion 61 knit the hole occupation rate less than 40%, then as shown in Figure 7, the probability that the part of being surrounded by island portion 61 in the surperficial Shanghai portion 62 that forms the island shape exists uprises.Therefore and not preferred at this moment, the air of discharging on the surface through exhaust channel during moulding loses institute, might become pin hole and residual.

In addition, when two faces all formed the island shape, the surface coverage of two faces all must be that preferred two faces of hole occupation rate of knitting of island portion 61 are all more than or equal to 40% more than or equal to 3%, smaller or equal to 80%.

Method for the prepreg of making embodiment three; From the following method of considerations such as productivity ratio is most preferred: support coating resin composition on the sheet at resin; To support on the face that the matrix resin that is coated with on the sheet sticks on reinforcement fabrics at this resin; Then; After pasting the diaphragm prevent that impurity from adhering to and wait on the another side of reinforcement fabrics, heating and/or pressurization and to reinforcement fabrics impregnation matrix resin, the reinforcement fabrics surface with the diaphragm side forms the island shape by pars fibrosa (extra large portion) formation that does not have resin combination on resin dipping part (island portion) that has matrix resin on the surface and the surface then.

Temperature, pressurized conditions when the heating condition of preferred especially this moment is moored smaller or equal to 5000 for the viscosity of the matrix resin of use are counted 49～780kPa with line pressure, thereby can make the prepreg with appropriate exhaust channel.When using composition epoxy resin, viscosity is 40～80 ℃ smaller or equal to the temperature of 5000 pools.

As the diaphragm that in the manufacturing approach of the prepreg of embodiment three, uses preferably with matrix resin fissility excellent protection film, can enumerate the silicone-treated processing release paper, polyethylene film etc. on surface excessively as its example.

In addition, support the resin molding that sheet also can use processing release paper and formed by polyolefin etc. as resin.And then; Also can preferably use the method for following formation island shape: when the coated substrates resin; The resin that use has male and fomale(M&F) supports sheet, matrix resin is coated on this resin supports on the sheet, then this resin is supported the matrix resin coated face and the reinforcement fabrics stickup of sheet; So only being coated on the matrix resin that resin supports on the protuberance on the sheet can transfer on the reinforcement fabrics, thereby forms island portion.

If use this method to make the prepreg of embodiment three, matrix resin mainly from reinforcement fabrics knit the hole to the inner dipping of prepreg, knit that the hole is oozed out and the fortifying fibre that impregnated near surface from opposition side (diaphragm side).Therefore, if use this method almost not cover the island portion of knitting bore portion.

In addition; Except that said method; Also can be, but this moment is also as stated through direct coated substrates resin or paste resin and support sheet and flood evenly or unevenly on the surface of the formation island of reinforcement fabrics shape, what matrix resin can be through fabric knits the surface impregnation of hole to opposition side; Therefore, the nearly all matrix resin in dipping back all is connected with the island portion that the hole is knitted in covering.

But, adopt this method also can make, be the immersion condition (temperature and pressure) that ideal value is used but need skilled adjustment to make the hole occupation rate of knitting of surface coverage and island portion.

Therefore, which kind of method no matter to make the prepreg of embodiment three with, matrix resin all can infiltrate innerly through knitting the hole from fabric face when dipping, and knits the hole from opposite side surfaces and oozes out, and therefore can think to exist hardly not have to flood the island portion of knitting the hole.

Embodiment four relates to following FRP moulding and uses intermediate materials: at least one face of the prepreg that is made up of matrix resin and fortifying fibre, paste the base material in fact do not flood compositions of thermosetting resin, the ratio (B)/(A) of the thickness (B) of thickness of above-mentioned prepreg (A) and base material is more than or equal to 0.1, smaller or equal to 2.5.

Matrix resin

As the matrix resin that is used for embodiment four, not special restriction, but from as operability, mouldability considerations such as the viscosity of prepreg and drapability, preferably use compositions of thermosetting resin.As the thermosetting resin that constitutes the compositions of thermosetting resin main component; Can enumerate epoxy resin, phenolic resins, bimaleimide resin, bismaleimide-triazine resin, cyanate ester resin, benzoxazine colophony etc.; Wherein, Because the mechanical property of the FRP that the cohesive of epoxy resin and fortifying fibre is excellent, obtain is excellent, so is preferred.In addition, phenolic resins is excellent in flame retardance not only, and is the matrix resin that is particularly suitable for the prepreg compound method of the mode of painting, and therefore can preferably use.

Fortifying fibre

Fortifying fibre as the prepreg that is configured for embodiment four; Not special restriction; Can use glass fibre, carbon fiber, aramid fibre, boron fibre, gather penylene benzo-dioxazole fiber etc. as its raw material all is high strength, elastomeric fortifying fibre; Wherein, be raw-material fortifying fibre because spring rate and intensity balance are excellent, its superior of FRP of obtaining with glass fibre, carbon fiber, therefore preferred the use.

The manufacturing approach of prepreg

In addition; Manufacturing approach as the prepreg that uses in the embodiment four; Can be above-mentioned heat fusing mode, but when using the prepreg made from the japanning mode, owing to the moulding article that obtain not having internal voids and surface pinholes with baking molding; If therefore particularly use the prepreg made from the japanning mode, can bring into play effect of the present invention significantly.

So-called japanning mode is the manufacturing approach of carrying out the prepreg of desolventizing after being impregnated into the compositions of thermosetting resin with solvent dilution in the fortifying fibre again.As method to the fortifying fibre dipping solution; Can be set forth in flood in the compositions of thermosetting resin solution fortifying fibre or make solution attached to cylinder on and that it is transferred to fortifying fibre is first-class; But dipping fortifying fibre in solution and the method for flooding at compositions of thermosetting resin solution to excellent aspect the dipping property of fortifying fibre, thereby preferred.In addition, for desolventizing, can enumerate the method for warm braw or heated-air drying, drying under reduced pressure etc., be preferred aspect productivity ratio but be to use the warm braw drying.

Prepreg and base material

FRP moulding of the present invention is pasted the base material that does not flood compositions of thermosetting resin with intermediate materials and is constituted at least one face of above-mentioned prepreg.Through the effect of this base material performance exhaust channel, in forming process, discharge the inner air that is detained and become easily, so play the space that prevents to produce in the moulding article and the effect of moulding article surface pinholes.If two faces at prepreg are pasted base material; Then exhaust channel is bigger than the situation of only pasting at a face; Therefore also preferred sometimes, still, owing to viscosity diminishes on two faces; Thereby the situation that can have the operability difference, so base material only sticks on the face, another side remains prepreg and is mostly preferred with the state of keeping viscosity.

The FRP of embodiment four moulding with intermediate materials in, base material is brought into play the effect of exhaust channel in forming process as stated, becoming derives the external path of moulding with the air in the formed body.But, on the other hand, be impregnated into after moulding that matrix resin in the fortifying fibre also is impregnated in the base material and integrated in forming process, thereby must obtain not having the article shaped of space and pin hole.Therefore, base material must have sufficient pore volume as exhaust channel, simultaneously must be the pore volume that matrix resin can its space of thorough impregnation in forming process.Therefore, the pore volume of the base material that the prepreg that uses in formation and the embodiment four adapts becomes key, and the result of research finds can form desirable pore volume through the thickness ratio of controlling prepreg and base material.Particularly, the ratio (B)/(A) of the thickness (B) of thickness of prepreg (A) and base material be necessary for more than or equal to 0.1, smaller or equal to 2.5.As stated, must to have sufficient space and its space as exhaust channel must be the size that matrix resin can thorough impregnation in forming process to base material.Therefore, special in the present invention preferred lower limit value is more than or equal to 0.15, more preferably more than or equal to 0.2.But, less than the sufficient space that in base material, can not guarantee as exhaust channel in 0.1 o'clock, sometimes can residual air after moulding.In addition, higher limit surpasses 2.5 more more preferably smaller or equal to 1.5, be preferably smaller or equal to 1.1 especially, and matrix resin can not thorough impregnation in the forming process, can residual air after the moulding.

The thickness measurement of prepreg and base material

Here, the thickness (B) of thickness of prepreg (A) and base material adopts the value of measuring with slide measure.But, must be noted that during mensuration that slide measure will compress prepreg and base material, thereby thickness does not change.Particularly for base material, when measuring owing to compress the Determination of thickness error maybe be big the time, preferably the photo through taking the base material cross section, amplify and confirm do not have to carry out method for measuring after the error.And then, when base material is sticked on two faces of prepreg, with the sum of thickness separately that sticks on the base material on each face as (B).

The formation of base material

As the raw material that constitute base material, can enumerate for example fibrous thermoplastic resin and fortifying fibre.When using fibrous thermoplastic resin, owing to can obtain the effect that interlayer strengthens during with intermediate materials in lamination FRP moulding of the present invention, therefore preferably.As so raw-material example; Can enumerate nylon, polyester, polyethylene, polypropylene etc., in addition, this moment is as raw-material shape; As long as can guarantee exhaust channel; Even as netted, also can use, draw neat shape also passable in a direction thermoplastic of bar-shaped or wire, and then the such shape of translation-angle lamination also can.But in order to ensure effective exhaust channel, most preferably thermoplastic resin is made up of fibrous material; Particularly can enumerate the fabric that constitutes by fibrous material, folk prescription to material or nonwoven etc.; Wherein, because nonwoven forms exhaust channel easily, therefore preferred especially.

In addition, as the raw material of this base material, also can preferably use also non-thermoplastic resin's fiber, particularly fortifying fibre.When using fortifying fibre as the raw material of base material, it both can be identical with the fortifying fibre that constitutes above-mentioned prepreg, also can be different.

Raw material as base material; When using the fiber identical with the fortifying fibre that constitutes prepreg; Can paste with the identical mode of orientation angles of the fortifying fibre of formation prepreg with the orientation angles of the fortifying fibre that constitutes base material; But when pasting both with different orientation angles, because the trouble of the lamination operation can omit quasi-isotropic lamination etc. the time is therefore preferred.In addition, so-called quasi-isotropic lamination be meant as lamination become [45 °/0 °/45 °/90 °] such, for the rerum natura of FRP does not produce anisotropy the orientation angles of each layer is not isotropically carried out lamination as FRP integral body.

On the other hand, in the fortifying fibre that constitutes base material, also can use the fortifying fibre different with the fortifying fibre that constitutes prepreg.This moment is owing to can make hybrid FRP simply, and is therefore preferred.For example; Use the fortifying fibre of formation prepreg to adopt the fabric that forms by glass fibre, the fortifying fibre that constitutes base material to adopt FRP the hybrid FRP for by glass/carbon fiber constitute of the FRP moulding of the fabric that forms by carbon fiber, can design cost performance best with the intermediate materials manufacturing.In addition, constitute the orientation angles of fortifying fibre with the fiber of the fortifying fibre that constitutes prepreg of base material this moment, both can be the same or different.

When using prepreg of the present invention or FRP moulding to make FRP with intermediate materials, the vacuum bag method of forming is the most preferred, adopts and utilizes the moulding of autoclave and compression moulding method also passable.

In the manufacturing approach of FRP of the present invention, preferably after solidifying more than 10 minutes or 10 minutes smaller or equal to 150 ℃ one-step solidification temperature next time, the method that is cured with temperature again more than or equal to the one-step solidification temperature.Particularly carrying out one-step solidification smaller or equal to 100 ℃, owing to can replace metal die, can only heat with steam with resinous mould, expense reduces, and is therefore preferred especially.

And then, after one-step solidification end, the demoulding,, can further shorten the molding time of high-temperature area if be cured in temperature once more more than or equal to the one-step solidification temperature, therefore preferred.

Prepreg of the present invention or FRP moulding form exhaust channel with intermediate materials in forming process, derive outside FRP through exhaust channel in the space, therefore are suitable for very much vacuum bag moulding, baking molding.

Be not limited to baking molding; When using prepreg of the present invention or FRP moulding with the intermediate materials moulding; Lamination prepreg of the present invention or FRP moulding with intermediate materials after, heat up after preferably vacuumizing, prepreg or FRP moulding fully being discharged with the air in the intermediate materials through exhaust channel.Specifically, preferably smaller or equal to the vacuum of 600mmHg, be more preferably less than and equal 700mmHg.If fully beginning to heat up before the exhaust, the viscosity of matrix resin reduces too much, before prepreg or FRP moulding are discharged with the air in the intermediate materials, stops up exhaust channel sometimes, and is therefore also not preferred.In addition, if return normal pressure in the forming process, the air of once discharging might be got back to prepreg or FRP moulding with in the intermediate materials, often is evacuated in the therefore preferred forming process.

And then when using prepreg of the present invention or FRP moulding with intermediate materials moulding FRP, preferably the viscosity of state before curing and matrix resin is solidified smaller or equal to keeping 1 hour under the state of 10000 pools or making it later more than 1 hour., can produce moving of matrix resin therebetween, inner air becomes easy to outside discharge of moulding article.More preferably under smaller or equal to the state of 5000 pools, keep making it later to solidify, and more preferably after keeping more than 2 hours or 2 hours under this state, make it to solidify.

As the method for using prepreg of the present invention or FRP moulding with intermediate materials moulding FRP, be smaller or equal to 1 ℃/minute to the programming rate of forming temperature preferably from hang down than forming temperature more than or equal to 20 ℃ temperature.After vacuumizing as stated; Keep vacuum state to heat up gradually, but if resin begins fast moving in the temperature-rise period, then at vacuum state, promptly at decompression state smaller or equal to 50Torr; Can the remaining gas of airtight trace and solidify, thus stay bedding void and surface pinholes.

Therefore, restriction in the temperature-rise period the resin translational speed so that last remaining micro-air also from moulding article discharge be necessary.For this reason, can reduce programming rate, if but temperature is too low, and then the viscosity of matrix resin is high, and moving of air is slow, thus matrix resin is impregnated into needing for a long time of sheet reinforcing-fiber substrate everywhere, and productivity ratio reduces may become problem.

Usually the viscosity of resin is minimum near forming temperature, if thus from beginning to make programming rate smaller or equal to 1 ℃ than the low temperature more than or equal to 20 ℃ of forming temperature, effect is very desirable.More preferably from beginning to make programming rate smaller or equal to 1 ℃ than the low temperature of forming temperature more than or equal to 30 ℃, especially preferred situation from beginning than the low temperature more than or equal to 40 ℃ of forming temperature.In addition, more preferably programming rate smaller or equal to 0.7 ℃/minute, especially preferably smaller or equal to 0.5 ℃/minute.

In addition; When intermediate materials is used in lamination prepreg of the present invention or FRP moulding; The situation that prepreg or FRP moulding can obviously be distinguished with the positive and negative of intermediate materials, the method for the face of lamination same side can positively form exhaust channel on equidirectional, and is therefore preferred.

Embodiment

Among the following embodiment 1～7 and comparative example 1～3, the even mixed mixture of resinous principle shown in following is used as matrix resin.Mixing condition is following.Whole compositions that will be except that DICY7 and DCMU99 evenly mix with the mixer that is set in 100 ℃, then, the temperature of mixer are dropped to 50 ℃, add DICY7 and DCMU99 and evenly mix.

Matrix resin composition

40 mass parts ェピコ, one ト 828 (bisphenol A type epoxy resin that japan epoxy resin (strain) society makes)

40 mass parts ェピコ, one ト 1001 (bisphenol A type epoxy resin (room temperature is a solid) that japan epoxy resin (strain) society makes)

20 mass parts ェピ Network ロ Application N740 (phenolic resin varnish type epoxy resin that Japanese ink chemical industry (strain) society makes)

5 mass parts DICY7 (the dicyano diamides that japan epoxy resin (strain) society makes)

5 mass parts DCMU99 (protecting 3 of chemical (strain) society of native ケ paddy manufacturing, 4-dichlorophenyl-N, N-dimethyl urea)

In addition, material, the evaluation method in each embodiment, comparative example, used are described below.

The short fiber that forms by thermoplastic resin

Utilizing melt spinning is 200 spies with nylon 12 spinning to short fiber fiber number, prepares to cut into the short fiber of length 5mm.Below, only be called short fiber.

Compressive strength after the impact

The mensuration of the compressive strength after the impact is to measure the compressive strength after 270lb-in impacts according to the method SRM2-88 that the most advanced and sophisticated composite association of business suppliers of the U.S. (SACMA) is recommended.

The assay method of Tg

The viscoplasticity spectrometer that uses the RDA-700 of レォメトリッ Network ス society manufacturing or have identical performance is measured the dynamic stiffiness rate G ' of sample near 0 ℃, with 2 ℃/minute programming rates intensifications.Show the mensuration result obtain with Fig. 8, as shown in the figure, transverse axis is that the logarithm that temperature, the longitudinal axis are got G ' is made chart, is connected to the line L1 of glassy zone, the line L2 of transport zone, is Tg (with reference to Fig. 8) with the temperature of its intersection point C.

MV minium viscosity

The determination of viscoelasticity device (RDA200) that uses レォメトリッ Network ス society to make is that 5 ℃/minute, angular speed are that 10rad/sec measures the intensification viscosity from room temperature (23 ℃) to 150 ℃ with programming rate.With the MV minium viscosity of the minimum in the viscosity that shows this moment as this resin combination.

Surface coverage

On the prepreg surface that forms the island shape, to use 40 ℃, pressure be 1 atmospheric metal system pressurized, heated roller with the level and smooth and transparent thickness of speed stickup of 5m/min is the polyethylene film of 20 μ m.Use 2,000,000 pixels or the above CCD camera should the surface; The image analysis system [high meticulous image analysis " IP1000 "] that uses rising sun engineering Co., Ltd. to make then; With thermosetting resin stick on the polyethylene film and the area at the position of tone variations as the area that is covered by thermosetting resin, obtain surface coverage by this value and the ratio of the whole surface area of prepreg.

The hole occupation rate is knitted by island portion

Likewise on prepreg, to use 40 ℃, pressure be 1 atmospheric metal system pressurized, heated roller with the level and smooth and transparent thickness of speed stickup of 5m/min with the surface coverage assay method is the polyethylene film of 20 μ m; After being cut into 10cm * 10cm; With the prepreg surface that the CCD camera has been pasted this polyethylene film, use above-mentioned image analysis system measurement heat-curing resin to stick on the polyethylene film and the number (T: island portion number) at the position that tone changes.

Subsequently, peel off polyethylene film, with CCD camera prepreg surface, the reinforcement fabrics of using image analysis apparatus to measure to be positioned at the face side that forms the island shape knit number of perforations (Y), knit the hole occupation rate from what formula (1) calculated island portion then.

FRP ocular estimate (free of pinholes is arranged)

According to after the method stated, on the surface of the FRP of the flat board of making, push after the chalk limit wipes whole on the limit, cleans the surface lightly with dried cloth etc., has shown free of pinholes thus, evaluation has free of pinholes.

FRP has tight

Vertically cut at thickness direction near the center of FRP of the flat board of confirming to have free of pinholes, take a picture with 20 times multiplying powers and take this cross section.Estimated tight according to observing this cross-section photograph.

Viscosity is estimated

Sticking on through thickness at the prepreg that will uprightly play back cut growth 10cm * wide 10cm under the environment of 23 ℃ of temperature, humidity 50% perpendicular to ground is on the releasing agent of the 2mm iron plate of handling, places also not peel off the prepreg that is pasted on iron plate after 1 minute then to be judged as the surperficial viscosity of prepreg good.

Embodiment 1

On processing release paper with 430g/m ²Resin weight per unit area coated substrates resin combination and prepare resin molding equably.(the fiber weight per unit area is 646g/m to the carbon fibre fabric TRK510 that makes from Li Yang society of Mitsubishi ², 2/2 twill weave) downside supply with this resin molding, resin is impregnated in the carbon fibre fabric.Dipping temperature is set at 60 ℃, regulates pressure and prepares prepreg.The resin impregnation rate of the prepreg that mensuration obtains is 90%, and affirmation is a prepreg of the present invention.

Then, the prepreg of the present invention that obtains as instrument (corrosion resistant plate) side, 4 layers of 0 ℃ of laminations with the face of processing release paper side.At this moment, the mode that lumps together with the face of the face of processing release paper side after the 2nd layer and opposition side is carried out lamination.Carry out the vacuum bag moulding, the baking molding length of side is the square plate of 30cm.Operability such as the lamination operation of prepreg are no problem fully.

The condition of molding of prepreg lamination body is following.Be warmed up to 50 ℃ with 3 ℃/minute from room temperature; Then 50 ℃, the decompression of 20Torr down maintenance carried out exhaust in 30 minutes; The decompression state limit of keeping 20Torr with the back is warmed up to 120 ℃ with 1 ℃/minute, keeps 1 hour at 120 ℃, obtains the square plate that the length of side is 30cm thus.

The plate that obtains does not have surface void yet, and the central part of cutting plate and after confirming the cross section, yet can't see the space in inside.

Comparative example 1

Except dipping temperature being set at 70 ℃, likewise prepare prepreg with embodiment 1.The cross section of observable prepreg, resin move to a side opposite with the processing release paper side, and the resin impregnation rate is 100%.With embodiment 1 likewise this prepreg of lamination, profiled sheeting.Operability such as lamination operation are no problem fully, but confirmed to have pin hole by the surface of the plate of moulding.And with embodiment 1 likewise behind the central part cross section of access panel, confirming has a large amount of spaces in inside.

Comparative example 2

Likewise prepare resin molding, preparation prepreg with embodiment 1.But be in room temperature, only add and depress enforcement as the condition of impregnating resin in carbon fibre fabric.Dipping does not almost carry out, and can't see resin fully with the opposite side of face of supplying with resin.The resin impregnation rate of the prepreg that mensuration obtains is 30%.With embodiment 1 likewise this prepreg of lamination, profiled sheeting.Face with the processing release paper side is implemented lamination as tool side.

The plate that obtains confirms that on the surface some pin holes are arranged, and likewise observes the central part cross section with embodiment 1, confirms to have internal voids.

The carbon fibre fabric TR3110 (several 3000 of fiber, plain weave, the weight per unit area 200g/m that make in Li Yang society of Mitsubishi ²) in embodiment 1 impregnating resin composition likewise, obtain prepreg of the present invention.Measuring the resin impregnation rate is 70%.With 16 layers of this prepreg of mode lamination of [0 °/45 °/90 °/-45 °/0 °/45 °/90 °/-45 °/-45 °/90 °/45 °/0 °/-45 °/90 °/45 °/0 °], the moulding length of side is the square plate of 1m.The face of processing release paper side is carried out lamination as tool side.Operability such as lamination operation are no problem fully.

Obtain the square plate that the length of side is 1m with following condition of molding: be warmed up to 45 ℃ from room temperature with 5 ℃/minute; Under 45 ℃, the decompression of 7Torr, keep carrying out in 60 minutes exhaust; Be warmed up to 80 ℃ with 2 ℃/minute subsequently, be warmed up to 120 ℃ from 80 ℃, kept 1 hour at 120 ℃ again with 0.7 ℃/minute.

The plate that obtains does not have surface pinholes yet, likewise observes inside with embodiment 1, but confirms not have the space.

Embodiment 4

Use the composition epoxy resin #830 of Li Yang society of Mitsubishi manufacturing as matrix resin.Use this resin and embodiment 1 likewise to prepare resin molding, and it is impregnated among the TRK510.But dipping temperature is set at 50 ℃.The resin impregnation rate of the prepreg that mensuration obtains is 60%, and it is prepreg of the present invention that the prepreg that obtains is confirmed.Use the moulding article of this prepreg moulding shape shown in Figure 3.Use wooden former as mould.Laminated structure is made 8 layers with the mode of [0 °/45 °/90 °/-45 °/-45 °/90 °/45 °/0 °], as tool side, and makes the face of processing release paper side and the face of its opposition side carry out lamination in the face of processing release paper side with lumping together.Operability such as lamination operation are no problem fully.

Obtain the moulding article with following condition of molding: be warmed up to 45 ℃ with 2 ℃/minute from room temperature, under 45 ℃, the decompression of 2Torr, keep carrying out exhaust in 4 hours, be warmed up to 80 ℃ with 0.5 ℃/minute subsequently, kept 2 hours at 80 ℃ again.

Surface at the moulding article that obtain does not have pin hole, and cuts inner and the observation cross section, and affirmation does not have the space.

Embodiment 5

Use the resin that uses among the embodiment 1, use (+45 °: carbon 267g/m of the no crimped fibre fabric Quadraxial-Carbon-Gelege that SAERTEX society makes as the sheet reinforcing-fiber substrate ², 0 °: carbon 268g/m ²,-45 °: carbon 267g/m ², 90 °: carbon 268g/m ², sew up: polyether sulfone 6g/m ², weight per unit area 1076g/m ²), likewise prepare prepreg with embodiment 1.But the resin weight per unit area is set at 717g/m ²Measuring the resin impregnation rate is 75%, and affirmation is a prepreg of the present invention.Make direction likewise 2 layers of laminations and the moulding FRP of the face of this prepreg.Condition of molding be with the same condition of embodiment 1 under implement.The article shaped that obtains can't see the space in inside, also can't see pin hole from the teeth outwards.

Embodiment 6

In 100 mass parts thermosetting resins, add 8.1 mass parts short fibers, evenly mix with mixer, obtain compositions of thermosetting resin at 50 ℃.

Then, use roll to be 133g/m with the resin weight per unit area ²On processing release paper, be coated with said composition.From carbon fibre fabric TR3110 (the fiber weight per unit area 200g/m that makes as the Li Yang society of Mitsubishi of sheet reinforcing-fiber substrate ², plain weave) a side at room temperature supply with the resin molding that obtains, be heated to 40 ℃, and, make resin not move by side to opposition side and prepare prepreg of the present invention from supplying with one of resin with roller pressurization.Measuring the resin impregnation rate is 60%.

With the prepreg that the differently-oriented directivity (warp) of fiber obtains for totally 24 layers the mode lamination of [45 °/0 °/-45 °/90 °/45 °/0 °/-45 ° // 90 °/45 °/0 °/-45 °/90 °/90 °/-45 °/0 °/45 °/90 °/-45 °/0 °/45 °/90 °/-45 °/0 °/45 °], baking molding and the plate of moulding 500mm * 500mm.Obtain the CFRP plate with following condition of molding: after the lamination of prepreg, at first laminate is vacuumized,, then, get back to normal pressure, kept 1 hour at 130 ℃ again 80 ℃ of heating 2 hours then 50 ℃ of heating 2 hours.Programming rate is 0.5 ℃/minute, is 2 ℃/minute in the cooling rate of 130 ℃ of maintenances after 1 hour.

The CFRP plate that obtains does not have pin hole yet, and outward appearance is very good, and the cutting plate central part, can't see the space in inside.By the test film that the plate that obtains cuts out, measure the compressive strength after impacting, consequently the so very high value of 262MPa.

Comparative example 3

Likewise prepare prepreg with embodiment 6.But strengthening dipping with the sheet reinforcing-fiber substrate when integrated, roughly do not having the part of resin on dipping to the face opposite with a side of supplying with resin.The resin impregnation rate is 100%.

Prepreg with embodiment 6 lamination moulding likewise obtains obtains the CFRP plate.This CFRP plate is seen pin hole, and outward appearance is also bad.And behind the cutting plate central part, see a large amount of spaces in inside.Use this plate to measure the compressive strength after impacting, consequently be low to moderate 222MPa.

Embodiment 7

As the sheet reinforcing-fiber substrate use with TR50S-12L a direction draw neat and with the formed folk prescription of polyester suturing with thread management to sewing up reinforcement with sheet reinforcing-fiber substrate (fiber weight per unit area 200g/m ²), fully likewise obtain prepreg of the present invention with embodiment 6 in addition.The resin impregnation rate of the prepreg that obtains is 45%.

Prepreg with embodiment 6 lamination moulding likewise obtains obtains the CFRP plate.Behind the central part of cutting plate, can't see the space in inside.Likewise measure the compressive strength after impacting by the plate that obtains with embodiment 6, its result demonstrates the such high value of 325MPa.

Comparative example 4

Likewise prepare prepreg with embodiment 7.But flooding when integrated with the sheet reinforcing-fiber substrate, dipping is to from also having resin to occur with the opposite side of a side of supplying with resin, and the resin impregnation rate is 100%.

Prepreg with embodiment 7 lamination moulding likewise obtains obtains the CFRP plate.Behind the cutting plate central part, see the space in inside.Use this plate and embodiment 6 likewise to measure the compressive strength after impacting, consequently low than embodiment 7, it is 283MPa.

Embodiment 8

Use carbon fibre fabric TRK510 (the fiber weight per unit area 646g/m of Li Yang society of Mitsubishi manufacturing as (A) sheet reinforcing-fiber substrate ², 2/2 twill weave, thickness 335 μ m), use the epoxy resin #830 that make in the Li Yang society of Mitsubishi that 80 ℃ of heating can be solidified in 2 hours as (B) curable resin composition.

On processing release paper with 175g/m ²Weight per unit area coating should (B) hardening resin composition.With the hardening resin composition face respectively as tow sides inboard, that this processing release paper sticked on (A) sheet reinforcing-fiber substrate.The stickup condition is to paste in the viscosity of room temperature utilization (B) hardening resin composition.After the FRP moulding of the present invention that obtains like this of cutting is observed inside with intermediate materials, confirm that part that being cured property resin combination not floods is at inner continued presence.

At the prepreg of the present invention that 10 layers of equidirectional laminations obtain, the CFRP plate of moulding 800mm * 800mm.Condition of molding is following: after confirming that atmospheric pressure drops to smaller or equal to 700mmHg, heat up from room temperature with 1 ℃ of/minute intensification speed, kept 3 hours at 50 ℃, continue to heat up again, solidified laminate in 2 hours 80 ℃ of heating.In addition, using DSR200 that レォメトリッ Network ス society makes is 3500 pools with the #830 of 2 ℃ of/minute intensification velocity determinations 50 ℃ viscosity.

Pin hole is can't see on surface at the CFRP plate that obtains fully.And cut the central part of this FRP plate and the access panel cross section does not observe internal voids yet.

Comparative example 5

Use the material preparation prepreg same with embodiment 8.But with the resin weight per unit area is 350g/m ²Be coated with, only paste in a side of (A) sheet reinforcing-fiber substrate.Use intermediate materials with the FRP moulding that embodiment 1 moulding likewise obtains, obtain the FRP plate.

Pin hole is can't see on surface at the FRP plate that obtains, but cuts central part and observe the cross section, sees a large amount of little internal voids.

Comparative example 6

Use the material preparation prepreg same with embodiment 8.With embodiment 8 be 175g/m likewise with the resin weight per unit area ²Be coated with, but not only just paste, also pass through the pressing of melt pressure machine 2 times, make it to flood fully with 60 ℃, 0.1MPa, the 25cm/ condition of dividing from the positive and negative of (A) sheet reinforcing-fiber substrate.The prepreg that obtains of cutting and observe the cross section, hardening resin composition is impregnated into inside, can see the part that does not have hardening resin composition everywhere, but each several part all being cured property resin combination cut off.

In addition, the prepreg with embodiment 8 moulding likewise obtains obtains the FRP plate.A large amount of pin holes are seen on surface at the FRP plate that obtains.And cutting central part and observe the cross section, see a lot of big and small internal voids.

Embodiment 9

Likewise prepare prepreg with embodiment 8.But can solidify in 2 hours at 80 ℃, heating as (B) hardening resin composition; At 55 ℃ the resinous principle shown in following is mixed to evenly; Use the composition epoxy resin that mixes, the weight per unit area when on processing release paper, being coated with (B) hardening resin composition is set at 215g/m ²

70 mass parts ェピコ, one ト 1001 (bisphenol A type epoxy resin (room temperature is a solid) that japan epoxy resin (strain) society makes)

10 mass parts ノバキュァ HX3722 (the recessive curing agent of the microcapsule-type that society of (strain) Asahi Chemical Industry makes)

5 mass parts ォミキュァ 94 (PTI Japan system amine curing agent)

The prepreg that use obtains is likewise made the CFRP plate with embodiment 8.On the CFRP plate surface that obtains, can't see pin hole fully.And cut the central part of this CFRP plate and observe the cross section, inside does not observe the space yet.And then after measuring the bending strength of the CFRP plate obtain according to ASTM D790, demonstrate the high strength of 680MPa.

Comparative example 7

Likewise prepare prepreg with embodiment 9.But behind the stickup resin molding, under the condition that 60 ℃, 0.1MPa, speed 25cm/ divide 2 times through the pressing of melt pressure machine, dipping fully thus.Cut the prepreg that obtains and observe the cross section, matrix resin is impregnated into inside, can see the part that does not have matrix resin everywhere, but each several part is all cut off by matrix resin composition, and is discontinuous.

The prepreg that use obtains is likewise made the CFRP plate with embodiment 9.A large amount of pin holes are seen on surface at the CFRP plate that obtains.And cutting central part and observe the cross section, see a lot of big and small internal voids.In addition, cut the central part of this CFRP plate and observe the cross section, do not observe internal voids.And then measure the bending strength of the CFRP plate obtain according to ASTM D790, and it is the value lower than embodiment 9, it is 420MPa.

Embodiment 10

Use roll to carry out at a side surface being 133g/m with weight per unit area on the processing release paper of demoulding processing ²Even epoxy resin coating composition (#340, MV minium viscosity 20 pools that the beautiful sun of Mitsubishi (strain) is made).The resin combination side that supports sheet at this resin is pasted carbon fibre fabric (TRK510 (the fiber weight per unit area 646g/m that Li Yang society of Mitsubishi makes ²)).And then the face that will implement to handle with the demoulding of above-mentioned same processing release paper makes the carbon fibre fabric side, carries out overlapping from this carbon fibre fabric side.Through its pressurization and heating being obtained prepreg with two pair rollers that are heated to 40 ℃.

The surface coverage of its resin combination of prepreg that obtains is 3%, and the hole occupation rate of knitting that resin combination is present in the island portion on surface is 60%.In addition, the result of operability evaluation is, sticks on well on the iron plate, and viscosity also is judged as well.

Use this prepreg, make FRP with following method.

10 tablets by prepreg cut growth 20cm * wide 20cm are carried out lamination.This laminate is configured on the iron substrate of handling with releasing agent on the surface (thickness 2mm).And then to cover the poly tetrafluoroethylene, the weight per unit area that have the hole of diameter 2mm at interval with 10cm successively be 20g/m in the side from it ²Nylon cloth, weight per unit area be 40g/m ²Glass fibre non-woven.Airtight with nylon membrane to its covering.Then, on one side the airtight interior volume of nylon membrane is reduced pressure with the mode that remains on smaller or equal to 600mmHg, after one side is warmed up to 130 ℃ with 2 ℃ of/minute intensification speed from room temperature, kept 2 hours at 130 ℃, obtain FRP thus.

Implement above-mentioned evaluation for the FRP that obtains, the substrate-side appearance of the FRP of moulding does not have pin hole, is good, even when cross-section photograph is observed, does not observe the space in interlayer and the layer yet.

Embodiment 11～14

Use resin combination and the reinforcement fabrics same,, make the fiber reinforcement fabric prepreg of record in surface coverage such as the table 1 respectively through pressurizeing several times with the roller that is heated to 40 ℃ and heating with embodiment 10.The hole occupation rate of knitting of its island portion of all prepregs all is 60%.

Likewise estimate these prepregs with embodiment 10, consequently, the operability of all prepregs is all good, and the FRP outward appearance that obtains is also good, can't see the space.

Embodiment 15,16

With embodiment 11 likewise the surface coverage of preparing resin composition be 40% prepreg.Adjustment is with the dipping number of times of heating and pressurizing roller, and the hole occupation rate of knitting that obtains island portion is respectively 100% and 50% prepreg.Likewise estimate these prepregs with embodiment 10, consequently, the operability of all prepregs is all good, and the FRP outward appearance that obtains is all good and layer is interior also all can't see the space with interlayer.

Embodiment 17～21

Temperature when in embodiment 17, flooding is set at 60 ℃; The MV minium viscosity of raising composition epoxy resin as shown in table 2 in embodiment 18 and embodiment 19; In embodiment 20 and embodiment 21, make the weight per unit area fabric as shown in table 2, likewise make prepreg with embodiment 10 except the carbon fibre fabric that uses.All prepregs all viscosity are good, and the outward appearance of the FRP that obtains is also good, also do not observe the space.

Embodiment 22,23

MV minium viscosity is set at 1100 pools in embodiment 22, and the fiber weight per unit area is set at 1600g/m in embodiment 23 ², other sets value as shown in table 2 for, in addition, likewise makes prepreg with embodiment 10.The viscosity of these prepregs is good.On the other hand, the FRP that is obtained by this prepreg is observed internal voids, but does not have pin hole.

Embodiment 24

Except on processing release paper, being 266g/m with the weight per unit area ²Evenly beyond the coating; After likewise carrying out pressurized, heated with embodiment 10, peel off resin and support sheet, on this face, paste TR3110 with two pairs of warm-up mills; Stress folded and above-mentioned same processing release paper by the TR3110 that pastes from behind again; With two pairs of warm-up mill pressurized, heated that are heated to 40 ℃, peel off overlapping from behind processing release paper once more, obtain the prepreg that two faces form the island shape.

It is 50% that its two faces of the surface coverage of the prepreg that obtains add up to, and the hole occupation rate of knitting of island portion is 60%.This prepreg also sticks on the iron plate well, and viscosity also is judged as well.In addition, use this prepreg to implement above-mentioned moulding evaluation, the surface of the FRP of moulding does not have pin hole, and outward appearance is good, does not also observe the space.

Comparative example 8～10

Except the value of knitting hole occupation rate, fiber weight per unit area of setting the surface coverage shown in the table 3, island portion for, likewise make prepreg with embodiment 9, estimate.Consequently, surface coverage is lower than the comparative example 8 of embodiment 10, and its viscosity is poor, and operability is also poor.On the other hand, that compares the too high comparative example of surface coverage 9 with embodiment 10 and compare island portion with embodiment 10 knits the low comparative example of hole occupation rate 10, observes pin hole and bedding void, the moulding article of the outward appearance that is not being met and mechanical properties.

The acetone soln of the compositions of thermosetting resin that uses in embodiment 25～30, the comparative example 11～14 uses and will be solved homogeneously in by the composition epoxy resin (is solid in room temperature) that following compositions constitutes in the acetone and the composition epoxy resin of preparation is the acetone soln (the following epoxy solution that only is called) of 60 quality %.

Composition epoxy resin

50 mass parts ェピコ, one ト 828 (bisphenol A type epoxy resin (room temperature is a liquid) that japan epoxy resin (strain) society makes)

30 mass parts ェピコ, one ト 1004 (bisphenol A type epoxy resin (room temperature is a solid) that japan epoxy resin (strain) society makes)

Embodiment 25

With carbon fibre fabric パィロ Off ィ Le TRK510 (2/2 twill weave, the fiber weight per unit area 646g/m of carbon fiber as Li Yang society of the Mitsubishi manufacturing of warp and parallel ², thickness 0.57mm) be immersed in the epoxy solution and flood, with 40 ℃ heated-air dryings, desolventizing, obtaining resin content is 46.7 quality % (resin weight per unit area 564g/m ²) prepreg.Use slide measure to measure this prepreg, thickness (A) is 0.85mm.In this prepreg, use carbon fibre fabric パィロ Off ィ Le TR3110 (plain weave, the fiber weight per unit area 200g/m of carbon fiber as Li Yang society of the Mitsubishi manufacturing of warp and parallel as base material ², thickness (B) 0.23 mm), stick on the face to the orientation angles of warp and parallel and the same direction of prepreg, obtain the FRP moulding and use intermediate materials.(B)/(A) of this intermediate materials is 0.27, the fiber weight per unit area of whole intermediate materials is 846g/m ², resin content is 40 quality %.

On mould, paste the FRP moulding obtain face with the prepreg side of intermediate materials, with same orientation angles, make identical face on equidirectional ground 3 layers of laminations, baking molding is the flat board of 500mm * 500mm.Condition of molding is following.Promptly the programming rate with 3 ℃/minute is warmed up to 50 ℃ from room temperature under smaller or equal to this vacuum of 5Torr, keeps 3 hours at 50 ℃, is warmed up to 120 ℃ with 0.5 ℃/minute subsequently, keeps 2 hours at 120 ℃, obtains the FRP plate.

Although the FRP plate that obtains is a baking molding, and is as shown in table 4, can't see pin hole on the surface, and the central part of cutting FRP plate and observe inside, also can't see the space in inside.

Embodiment 26

Except resin content being set at 57.1 quality % (resin weight per unit area 861g/m ²), thickness (A) is beyond the 1.1mm, likewise prepares prepreg with embodiment 25.In the prepreg that obtains; Use the TRK510 of the thickness (B) identical as base material, stick on the face and obtain the FRP moulding and use intermediate materials from the differently-oriented directivity of the fortifying fibre of the prepreg 45 ° of ground that tilt as 0.57mm with the reinforcement fabrics that is used for prepreg.(B)/(A) of this intermediate materials is 0.52, and the fiber weight per unit area of whole intermediate materials is 1292g/m ², resin content is 40 quality %.

Use intermediate materials with the fiber orientation angles of warp for the FRP moulding that the mode lamination of [45 °/0 °/45 °/90 °/90 °/45 °/0 °/-45 °] obtains, with embodiment 24 baking molding and obtain the FRP plate likewise.But, because the intermediate materials in the present embodiment is 0 °/45 ° a two-layer structure, therefore 4 layers of laminations in this intermediate materials unit.

The FRP plate that obtains is as shown in table 4, outwardly less than pin hole, and the central part of cutting FRP plate and observe inside, also can't see the space in inside.

Embodiment 27

Use day east to spin the ロ one PVC Application グガラス Network ロス WR800 that society makes except replacing TRK510, resin content is set at 53.3 quality % (resin weight per unit area 450g/m ²), thickness (A) is beyond the 0.71mm, likewise obtains prepreg with embodiment 25.And then パィロ Off ィ Le TR3110 is sticked on the face in unidirectional mode at orientation angles and the prepreg with warp and parallel on this prepreg, the mixing FRP moulding that obtains glass fibre/carbon fiber is with intermediate materials ((B)/(A)=0.32).

With same orientation angles, make identical face on equidirectional ground 4 layers of intermediate materials of the present invention that obtains of lamination, with embodiment 25 likewise baking molding and obtain glass fibre/carbon fiber mix the FRP plate.If use intermediate materials of the present invention, moulding mixing FRP simply.

In addition, the FRP plate that obtains is as shown in table 4, and pin hole is can't see on the surface, and the central part of cutting FRP plate and observe inside, also can't see the space in inside.

Embodiment 28

Except resin content being set at 51.9 quality % (resin weight per unit area 697.5g/m ²), thickness (A) is beyond the 0.96mm, likewise prepares prepreg with embodiment 25.On positive and negative two faces that パィロ Off ィ Le TR3110 sticked on prepreg in unidirectional mode with the orientation angles and the prepreg of warp and parallel on the prepreg that obtains,, obtain FRP moulding of the present invention and use intermediate materials as base material.(B)/(A) of this intermediate materials is 0.24, the carbon fiber weight per unit area of whole intermediate materials is 1064g/m ², resin content is 40 quality %.

With same orientation angles, make identical face on equidirectional ground 10 layers of intermediate materials of the present invention that obtains of lamination, with embodiment 25 baking molding likewise, obtain the FRP plate.

The FRP plate that obtains is as shown in table 4, and pin hole is can't see on the surface, and the central part of cutting FRP plate and observe inside, also can't see the space in inside.

Embodiment 29

Except the substituted epoxy resin uses methanol solution, the phenolate 5900 (about 60 quality %) of the phenolic resins that Japanese ink chemical industry society makes, resin content is set at 57.1 quality % (resin weight per unit area 861g/m ²), thickness (A) is beyond the 1.1mm, likewise prepares prepreg with embodiment 25.Mode forming equidirectional with the differently-oriented directivity of carbon fiber on the prepreg sticks on パィロ Off ィ Le TR3110 on the face, obtains the FRP moulding and uses intermediate materials.(B)/(A) of this intermediate materials is 0.21, the fiber weight per unit area of whole intermediate materials is 1292g/m ², resin content is 40 quality %.

3 layers of intermediate materials of the present invention that obtains of lamination on same direction, the FRP plate of baking molding 1000mm * 1000mm.Condition of molding is under the vacuum smaller or equal to 5Torr, is warmed up to 90 ℃, kept 20 hours at 90 ℃ with 0.5 ℃/minute.

Comparative example 11

It is illustrated in the example of not pasting base material on the prepreg.Except resin content being set at 40.0 quality % (resin weight per unit area 431g/m ²), thickness (A) is beyond the 0.73mm, likewise prepares prepreg with embodiment 25.

Do not paste base material, only with 8 layers of prepreg that obtains of mode lamination of [45 °/0 °/45 °/90 °/90 °/45 °/0 °/-45 °], with embodiment 24 baking molding likewise, obtain the FRP plate.

The FRP plate that obtains is as shown in table 4, and a large amount of pin holes are seen on the surface, and the central part of cutting FRP plate and observe inside, also sees a large amount of spaces in inside.

Comparative example 12

Except resin content being set at 40.5 quality % (resin weight per unit area 430g/m ²), thickness (A) is beyond the 0.74mm, likewise prepares prepreg with embodiment 25.(thickness (B)=0.04mm) obtains the FRP moulding and uses intermediate materials as base material the glass fabric H20 F5 104 that stickup ュニチカグラス Off ァィバ one (strain) society makes on this prepreg.(B)/(A) of this intermediate materials is 0.05.

Obtain the FRP plate with intermediate materials with embodiment 25 this FRP moulding of baking molding likewise.The FRP plate that obtains is as shown in table 4, and pin hole is seen on the surface, and the central part of cutting FRP plate and observe inside, also sees the space in inside.

Comparative example 13

Except resin content being set at 32.0 quality % (resin weight per unit area 300g/m ²), thickness (A) is beyond the 0.62mm, likewise prepares prepreg with embodiment 25.On this prepreg, paste polyester fiber nonwoven (fiber weight per unit area 132g/m ², thickness (B)=0.04mm) is as base material, obtain the FRP moulding and use intermediate materials.This FRP moulding is 2.74 with (B)/(A) of intermediate materials.

Obtain the FRP plate with intermediate materials with embodiment 25 this FRP moulding of baking molding likewise.The FRP plate that obtains is as shown in table 4, and not dipping portion of a large amount of resins is seen on the surface, and the central part of cutting FRP plate and observe inside, also sees a large amount of spaces in inside.

Embodiment 30

With the fiber weight per unit area is 190g/m ²At the carbon fiber パィロ Off ィ Le TR50S-12L that folk prescription is made to the beautiful sun of La Qi Mitsubishi, likewise preparing resin content with embodiment 25 is 30.2 quality % (resin weight per unit area 82.3g/m ²), thickness (A) is the prepreg of 0.18mm.Nonwoven (the fiber weight per unit area 20g/m that on this prepreg, will process for nylon 12 fibers of 0.32mm by thickness (B) ²) stick on the face, obtain the FRP moulding with intermediate materials ((B)/(A)=1.78).

(so-called 3S representes that mode with plane symmetry sticks on together the structure behind 3 lamination repetitives of repetition with intermediate materials for the mode lamination of [45 °/0 °/45 °/90 °] 3S adds up to 24 layers of FRP moulding that obtains with the orientation angles of carbon fiber.That is, initial 12 layers with the carbon fiber side as die side, subsequently 12 layers in a side lamination carbon fiber side opposite with mould).Lamination in this wise is with embodiment 24 baking molding and obtain the FRP plate likewise.

Surface and interlayer at the FRP plate that obtains can't see pin hole, and the central part of cutting FRP plate and observe inside, also can't see the space in inside.The CAI (the remaining compressive strength after the impact) that carries out this plate measures.It is the SRM2-88 method enforcement according to SACMA that CAI measures.The impact that adds is set at 1500 inchpound/inches.The result that the CAI of the plate that consequently, obtains measures be 350MPa such be high value as FRP.

Comparative example 14

Except resin content being set at 35.0 quality % (resin weight per unit area 102.3g/m ²), thickness (A) is beyond the 0.19mm, likewise prepares prepreg with embodiment 25.With the mode of [45 °/0 °/45 °/90 °] 3S only lamination add up to 24 layers of prepreg that obtains.

The FRP plate that obtains, on the surface, interlayer sees some spaces, and the central part of cutting FRP plate and observe inside, also see the space in inside.In addition, the CAI of the plate that obtains measures, and it is low 210MPa.

Table 1

?	Embodiment 10	Embodiment 11	Embodiment 12	Embodiment 13	Embodiment 14	Embodiment 15	Embodiment 16
								Surface coverage (%)	3	20	40	60	80	40	40
The hole occupation rate is knitted by island portion	60	60	60	60	60	40	100
								MV minium viscosity (pool)	20	20	20	20	20	20	20
Fiber weight per unit area (the g/m of reinforcement fabrics ²)	650	650	650	650	650	650	650
								Outward appearance (free of pinholes is arranged)	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have
Tight is arranged	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have
								Viscosity	Well	Well	Well	Well	Well	Well	Well

Table 2

?	Embodiment 17	Embodiment 18	Embodiment 19	Embodiment 20	Embodiment 21	Embodiment 22	Embodiment 23	Embodiment 24
									Surface coverage (%)	60	60	60	60	60	60	60	50
Hole occupation rate (%) is knitted by island portion	50	50	50	50	50	60	60	60
									MV minium viscosity (pool)	20	950	100	500	500	1100	500	20
Fiber weight per unit area (the g/m of reinforcement fabrics ²)	650	650	650	50	1500	650	1600	400
									Outward appearance (free of pinholes is arranged)	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have
Tight is arranged	Do not have	Do not have	Do not have	Do not have	Do not have	Have	Have	Do not have
									Viscosity	Well	Well	Well	Well	Well	Well	Well	Well

Table 3

?	Comparative example 8	Comparative example 9	Comparative example 10
				Surface coverage (%)	2	81	70
Hole occupation rate (%) is knitted by island portion	60	60	35
				MV minium viscosity (pool)	20	20	20
Fiber weight per unit area (the g/m of reinforcement fabrics ²)	650	650	650
				Outward appearance (free of pinholes is arranged)	Do not have	Do not have	Have
Tight is arranged	Have	Have	Have
				Viscosity	Bad	Well	Well

Table 4

?	Embodiment 25	Embodiment 26	Embodiment 27	Embodiment 28	Embodiment 29	Embodiment 30	Comparative example 11	Comparative example 12	Comparative example 13	Comparative example 14
											The prepreg fortifying fibre	TRK510	TRK510	WR800	TRK510	TRK510	TR50S-12L	TRK510	TRK510	TRK510	TR50S-12L
The prepreg matrix resin	Epoxy resin	Epoxy resin	Epoxy resin	Epoxy resin	Phenolic resins	Epoxy resin	Epoxy resin	Epoxy resin	Epoxy resin	Epoxy resin
											Prepreg resin content (%)	46.7	57.1	53.3	51.9	57.1	30.2	40.0	40.5	32.0	35.0
Base material	TR3110	TRK510	TR3110	TR3110	TR3110	Nylon 12 fabric nonwoven cloths	Do not have	H20	The polyester fiber nonwoven	Do not have
											Prepreg thickness (mm) (A)	0.85	1.1	0.71	0.96	1.1	0.18	0.73	0.74	0.62	0.19
Base material thickness (mm) (B)	0.23	0.57	0.23	0.23	0.23	0.32	-	0.04	1.7	-
											(B)/(A)	0.27	0.52	0.32	0.24	0.21	1.78	-	0.05	2.74	-
Having or not of the space of FRP formed body and pin hole	Do not have	Do not have	Do not have	Do not have	Do not have	Do not have	Have	Have	Have	Have

TRK510: the carbon fibre fabric パィロ Off ィ Le TRK510 that Li Yang society of Mitsubishi makes

TR3110: the carbon fibre fabric パィロ Off ィ Le TR3110 that Li Yang society of Mitsubishi makes

WR800: the slubbing glass fabric WR800 that society makes is spun in day east

TR50S-12L: the folk prescription that the carbon fiber パィロ Off ィ Le TR50S-12L that is made by Li Yang society of Mitsubishi constitutes is to material

H20: the glass fabric H20 F5 104 that ュニチカグラス Off ァィバ one (strain) society makes

The possibility that industry is utilized

Keep and the same operability of prepreg in the past, simultaneously can be without autoclave, even only also can obtain the FRP that inside does not have space and surface pinholes, good appearance through the vacuum pressure moulding.

Claims

1. intermediate materials is used in a FRP moulding; It comprises the prepreg with fortifying fibre and matrix resin and is arranged on the base material that does not flood compositions of thermosetting resin in fact at least one side surface of prepreg; Wherein, Said FRP moulding is at least one side surface of said prepreg, to paste the base material that does not flood compositions of thermosetting resin to form with intermediate materials; Above-mentioned prepreg forms through dipping fortifying fibre in compositions of thermosetting resin solution, and the ratio (B)/(A) of the thickness (B) of the thickness of above-mentioned prepreg (A) and base material is more than or equal to 0.1, smaller or equal to 1.5.

2. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, matrix resin is a compositions of thermosetting resin.

3. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, the base material that does not in fact flood compositions of thermosetting resin contains fibrous thermoplastic resin.

4. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, the base material that does not in fact flood hardening resin composition is the nonwoven of thermoplastic resin.

5. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, the base material that does not in fact flood compositions of thermosetting resin contains fortifying fibre.

6. intermediate materials is used in FRP moulding as claimed in claim 5, it is characterized in that, fortifying fibre be be included in said prepreg in the identical fortifying fibre of fortifying fibre.

7. intermediate materials is used in FRP moulding as claimed in claim 5, it is characterized in that, fortifying fibre is configured with fortifying fibre in being included in said prepreg with becoming different angles.

8. intermediate materials is used in FRP moulding as claimed in claim 5, it is characterized in that, fortifying fibre be be included in said prepreg in the different fortifying fibre of fortifying fibre.

9. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, matrix resin is composition epoxy resin or phenol resin composition.

10. intermediate materials is used in FRP moulding as claimed in claim 1, it is characterized in that, the fortifying fibre that is included in the said prepreg is carbon fiber and/or glass fibre.

11. the manufacturing approach of fibre reinforced composites is characterized in that, intermediate materials is used in the described FRP moulding of lamination claim 1, through the moulding of the vacuum bag method of forming.