CN111746062A - 包含缝合构件的纤维增强复合结构体及其制造方法 - Google Patents

包含缝合构件的纤维增强复合结构体及其制造方法 Download PDF

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Publication number
CN111746062A
CN111746062A CN202010217145.2A CN202010217145A CN111746062A CN 111746062 A CN111746062 A CN 111746062A CN 202010217145 A CN202010217145 A CN 202010217145A CN 111746062 A CN111746062 A CN 111746062A
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China
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carbon
fiber
reinforced
composite structure
reinforced composite
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CN202010217145.2A
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English (en)
Inventor
俞在相
洪贤基
裴廓镇
郑哈娜
崔会吉
吴侑娜
李东原
杨澈玟
李旼昱
金珉局
罗元振
刘南浩
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Korea Advanced Institute of Science and Technology KAIST
Korea Institute of Science and Technology KIST
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Korea Advanced Institute of Science and Technology KAIST
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Publication of CN111746062A publication Critical patent/CN111746062A/zh
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Abstract

本说明书提供一种碳纤维增强复合结构体，其中，包含层叠的复数个碳增强纤维片材、以及贯通一个以上碳增强纤维片材的缝合构件，上述碳增强纤维片材包含沿一个方向排列的复数个碳增强纤维。上述碳纤维增强复合结构体沿厚度方向显示优异的热导率。

Description

包含缝合构件的纤维增强复合结构体及其制造方法
技术领域
本发明涉及纤维复合结构体及其制造方法，更详细地，涉及具有优异的机械强度，同时沿层叠方向热导率得到提高的纤维增强复合结构体。
对于国家支持研发的说明
本研究是在Kolon Plastic株式会社的主管下，得到大韩民国产业通商资源部(研究课题名：适用了利用PPS、PEEK且纤维含量为60wt％以上的碳纤维UD胶带的航空器用加固面板以及“C”、“Z”信道开发，课题固有号：1415158981)的支持而实施的。
另外，本研究是在韩国科学技术研究院的主管下，得到大韩民国科学技术信息通讯部(研究课题名：导电/导热碳纤维增强(CFRP)复合材料制作技术开发，课题固有号：1711082003)的支持而实施的。
背景技术
当前，碳纤维增强复合材料(CFRP)在航空航天、机动车、休闲运动产业等多方面领域中需求量正在逐渐增加。从目前机动车部件材料市场的观点来看，以减少二氧化碳和改善燃油效率为目的，BMW i3系列等中正在利用接近约50％的碳纤维增强复合材料。特别是，用于航空航天的碳纤维销售比重以占总体的约40％，显示为最高，认为这与高性能高、功能性材料的需求相对应。在航空领域中也不仅是战斗机，民用飞机A380(空客)、B787(波音)中整个结构体的20～50％的部件中也正在活跃地使用非刚性良好的复合材料。但是，在卫星产业，仅以太阳能电池板、承载体接触结构物等简单结构体的形式限制性地被使用。这是因为用于人工卫星的高发热性电气部件需要放入被板状部件包围的三明治式平台的狭窄内部空间，如果由机械驱动产生的热量没有顺利排出，则在寿命或管理方面产生制约。这时，如果使用碳纤维复合材料板状结构体，则由于在厚度方向导热差的碳纤维复合材料的特性，将无法排出热量。虽然现在广泛使用的单向(unidirectional)、双向(biaxial)复合材料层压板在平面方向热导率非常优异，但是沿厚度方向的热导率很低，因此，为了用作人工卫星的部件和内部结构体，需要开发及研究在厚度方向也能够良好地导热的碳纤维增强复合材料。
用于航天火箭或人造卫星的碳纤维复合材料主要使用具有高弹性模量(～900GPa)和高导热系数(～900W/mK)、低热膨胀系数的沥青(pitch)系碳纤维。但是，在使用聚丙烯腈(PAN)系碳纤维的情况下，与沥青系碳纤维相比而具有约1.5倍左右的拉伸强度(～6400MPa)。如果在人造卫星平台中由沥青系构成碳纤维复合材料，虽然具有高弹性模量、良好的导热系数，但强度相对不会很高，如果只由PAN系构成碳纤维复合材料，则在极低的导热系数下通过被禁锢的热量而对电气部件造成损伤。
因此，对于与现有的碳纤维复合材料相比拉伸强度也高、厚度方向的热导率也高的碳纤维复合材料的要求正在提高。
作为与沿厚度方向的传导性相关的研究，存在几种在碳纤维复合材料层叠板中进一步沿厚度方向插入及贯通纤维来增加厚度方向的传导性的发明。韩国申请号10-2016-0067262提出了对于利用针刺
Figure BDA0002424857530000021
使碳纤维贯通二维网而制造三维碳纤维织物的新制造工序的发明；US 2016/0347918 A1提出了关于具有沿厚度方向的导电性的可以适用于航空器的碳纤维复合材料的发明，其中，研究出以下层叠方式：层叠板状碳纤维复合材料时，沿垂直方向加入褶皱，或者上层和下层包裹中间层的形态，最顶层包裹下面各层的外侧端部，或者用具有传导性的金属钉等固定若干层等；并且，US 2010/0021682 A1提出了利用将碳纳米管(CNT)纤维、铜线等以玻璃纤维复合材料(对照组)的总体积的约5％左右进行缝合的方法，从而提高导热性的发明。
现有技术文献
专利文献
KR 10-2017-0135399 A1
US 2016/0347918 A1.
US 2010/0021682 A1.
发明内容
如上述的那样，本发明的实施方式想要解决单向(unidirectional)、双向(biaxial)复合材料层压板等具有的沿厚度方向的热导率低的问题。
另外，本发明的实施方式想要解决现有的复合材料在高发热、高温环境下仅选择性地具有拉伸强度和热导率的问题。
本发明的一实施方式提供一种碳纤维增强复合结构体，其中，包含层叠的复数个碳增强纤维片材、以及贯通一个以上碳增强纤维片材的缝合构件，上述碳增强纤维片材包含沿一个方向排列的复数个碳增强纤维。
在例示的实施方式中，相邻的碳增强纤维片材可以使碳增强纤维的排列方向彼此不同。
在例示的实施方式中，相邻的碳增强纤维片材可以使碳增强纤维的排列方向成90°而进行层叠。
在例示的实施方式中，上述碳增强纤维片材为预浸料，上述预浸料可以包含沿一个方向排列的复数个碳增强纤维和浸渗上述碳增强纤维的高分子树脂。
在例示的实施方式中，上述缝合构件可以包含选自PAN系碳增强纤维、沥青系碳增强纤维、以及氮化硼(BN)纤维中的一种以上。
在例示的实施方式中，上述碳增强纤维可以包含PAN系碳增强纤维，上述缝合构件可以包含沥青系碳增强纤维。
在例示的实施方式中，上述碳增强纤维和缝合构件可具有-1×10-6K-1至1×10-6K-1范围的热膨胀系数。
在例示的实施方式中，上述缝合构件可以沿碳增强纤维片材的厚度方向传递热量。
本发明的另一实施方式提供一种碳纤维增强复合结构体制造方法，其中，包括以下步骤：i)层叠复数个碳增强纤维片材的步骤；ii)将层叠的碳增强纤维片材中的一个以上的碳增强纤维片材用缝合构件贯通的步骤；以及iii)使层叠的碳增强纤维片材成型及固化而形成碳纤维复合结构体的步骤，上述碳增强纤维片材包含沿一个方向排列的复数个碳增强纤维。
在例示的实施方式中，上述i)碳增强纤维片材层叠步骤可以是使相邻的片材的碳增强纤维的排列方向彼此不同而层叠的。
在例示的实施方式中，上述碳增强纤维片材为预浸料，上述预浸料可以包含沿一个方向排列的复数个碳增强纤维和浸渗上述碳增强纤维的高分子树脂。
在例示的实施方式中，上述碳增强纤维可以包含PAN系碳增强纤维，上述缝合构件可以包含沥青系碳增强纤维。
在例示的实施方式中，上述ii)缝合构件贯通步骤可以包括使包含上述缝合构件的缝合针贯通并去除缝合针。
在例示的实施方式中，上述缝合针包括内部包含沿长度方向形成的贯通孔的主体、以及配置于上述贯通孔的缝合构件，上述主体的一端可以具有切断倾斜面。
在例示的实施方式中，上述切断倾斜面可以与主体形成50°-80°的角度。
在例示的实施方式中，上述成型及固化可以包括利用高压釜(AC)、烘箱成型、长丝缠绕(Filament Winding，FW)、树脂传递模塑(Resin Transfer Molding，RTM)、真空辅助树脂传递模塑(Vacuum assisted RTM，VaRTM)、预浸料压缩成型(Prepreg CompressionMolding，PCM)、或者注塑成型的工序。
在例示的实施方式中，上述成型及固化可以在50-150℃的温度下实施10-120分钟。
根据本发明的实施方式的纤维复合结构体可以具有沿厚度方向热导率增加约120％以上的优异的热导率。
另外，根据本发明的实施方式的纤维复合结构体作为同时具有优异的拉伸强度的纤维增强复合材料(FRP)，可以适用于航空航天、机动车、休闲运动产业等多方面领域。
另外，根据本发明的实施方式的纤维复合结构体制造方法提出可以将增强纤维的损伤最小化的缝合方法，可以是一种没有将增强纤维再次穿于缝合针的额外过程的简单工序。
附图说明
图1图示根据本发明的实施方式的纤维增强复合结构体的模式图。
图2a至2g表示对根据本发明的实施方式的纤维增强复合结构体中层叠的增强纤维片材缝合缝合构件的过程。
图3a和3b表示对层叠的增强纤维片材的背面贯通缝合构件的位置(图3a)，表示通过其而制作的实施例和比较例的样品试样的照片(图3b)。
图4图示根据本发明的实施方式的纤维增强复合结构体制造方法的流程图。
具体实施方式
下面，参考附图来详细地说明本发明的优选实施例。
本文中公开的本发明的实施例是以仅用于说明的目的例示的，本发明的实施例可以实施为各种形态，不可以解释为限定于本文中说明的实施例。
本发明可以加以各种变更，可以具有各种形态，实施例并不是为了将本发明限定为特定的公开形态，应当理解为将本发明的思想和技术范围中包含的所有变更、等同物乃至替代物都包括在内。
单数的表现如果在上下文中未明确不同地意指，就包含复数的表现。在本申请中，“包含/包括”或者“具有”等用语是为了指定存在说明书中记载的特征、数字、步骤、动作、构成要素、部件或它们的组合，应该理解为没有事先排除一个或一个以上其它特征或数字、步骤、动作、构成要素、部件或它们的组合的存在或者附加可能性。
在本说明书中，用语“缝合”是指将丝束(tow)形态的增强纤维贯通于增强纤维片材，从而使增强纤维片材和增强纤维一体化来进行加固。
在本说明书中，用语“热膨胀系数(Coefficient of thermal expansion)”是指对某物体加热时，温度每上升1℃时膨胀的长度的变化。
纤维增强复合结构体
在本发明的一实施方式中，提供一种纤维增强复合结构体，其中，包含层叠的复数个增强纤维片材、以及贯通一个以上增强纤维片材的缝合构件，上述增强纤维片材包含沿一个方向排列的复数个增强纤维。
在一实施方式中，上述增强纤维片材的增强纤维可以为纤维素增强纤维、玻璃增强纤维、或者碳增强纤维，例如，上述增强纤维片材可以为碳增强纤维片材。通常已知碳纤维增强复合材料(CFRP)与玻璃纤维增强复合材料(GFRP)相比，杨氏模量(Young’smodulus)、泊松比(Poisso n’s ratio)、剪切模量(shear modulus)等各物理特性显著地高，具体而言，与GFRP相比，在杨氏模量、泊松比、剪切模量等各物性方面，CFRP更优异。特别是掌握到，与用玻璃纤维制造的环氧复合材料相比，碳纤维增强复合材料的极限应力(Ultimate stress)以35度为基准时高约6～10倍左右。另外，已知在进行测定弯曲强度的弯曲实验(flexural test)时，C FRP的极限应力(Ultimate stress)与GFRP的应力(stress)值相比高4倍以上。因此，根据本发明的碳纤维增强复合结构体与其它材料的复合材料例如玻璃纤维等相比，可以具有优异的物性。
在一实施方式中，相邻的增强纤维片材可以使增强纤维的排列方向彼此相同或者彼此不同。具体而言，相邻的增强纤维片材之间的增强纤维的排列方向彼此相同时，即沿单向(Unidirectional，UD)排列时，侧面强度可能减弱，相反，可能沿一个方向具有优异的强度特性。此外，具体而言，相邻的增强纤维片材之间的增强纤维的排列方向彼此不同时，即增强纤维片材中沿一个方向排列的增强纤维与相邻的片材的排列方向不同时，可以使物理特性提高。
例如，相邻的增强纤维片材可以使增强纤维的排列方向成0°、45°、或90°而层叠，优选地，相邻的增强纤维片材可以使增强纤维的排列方向成90°而层叠。
在一实施方式中，上述复数个增强纤维片材的厚度可以根据适用的厚度来改变层数。例如，上述复数个增强纤维片材可以层叠为2层以上。增强纤维片材层叠小于2层时，增强纤维片材中沿一个方向排列的增强纤维由于不可能实现相邻的片材改变排列方向而进行层叠，因此可能难以带来物性的提高。
在一实施方式中，上述增强纤维片材可以包含增强纤维，上述增强纤维可以为纺织或非纺织增强纤维。具体而言，上述纺织增强纤维可以包含单向(Unidirectional，UD)织物、经编织物(NCF)、平织、斜织、丝织、方平织等纺织的碳纤维。
在一实施方式中，上述增强纤维可以为碳增强纤维，此外，上述碳增强纤维可以包含PAN系碳增强纤维或沥青系碳增强纤维。优选地，包含在上述增强纤维片材中的碳增强纤维可以包含PAN系碳增强纤维，在使用上述PAN系碳增强纤维的情况下，具有约1.5倍左右的拉伸强度(～6400MPa)，因此可以得到优异的物性。
在一实施方式中，上述增强纤维片材为预浸料，上述预浸料可以包含沿一个方向排列的复数个增强纤维和浸渗上述增强纤维的高分子树脂。
在一实施方式中，上述高分子树脂可以包含环氧树脂或氨基甲酸酯树脂。上述高分子树脂通过聚合反应而固化，从而可以在碳材料片材中形成矩阵。例如，上述高分子树脂可以包含热固性树脂、热塑性树脂、缩合树脂，上述热固性树脂可以包含双酚型、酚醛清漆型、芳香胺型、或者脂环型环氧树脂等，上述热塑性树脂可以包含尼龙、聚碳酸酯、聚砜、聚醚砜
Figure BDA0002424857530000071
聚醚醚酮(PEEK)等，上述缩合树脂可以包含聚醚树脂
Figure BDA0002424857530000072
乙烯基醚树脂
Figure BDA0002424857530000073
等。
在一实施方式中，上述缝合构件可以贯通增强纤维片材，纤维增强复合结构体可以包含一个以上的缝合构件。具体而言，复数个缝合构件可以独立地贯通增强纤维片材，例如，一个缝合构件可以贯通层叠的增强纤维片材，其它的缝合构件可以独立地贯通层叠的增强纤维片材。在一实施方式中，上述缝合构件可以为由复数个碳增强纤维例如数千丝的碳增强纤维构成的，上述缝合构件可以包含选自PAN系碳增强纤维、沥青系碳增强纤维、以及氮化硼(BN)纤维中的一种以上。优选地，上述缝合构件可以为沥青系碳增强纤维，上述沥青系碳增强纤维具有高弹性模量(～900GPa)、高导热系数(～900W/mK)、以及低热膨胀系数，因此坚固纤维增强复合结构体的内部结构，或者具有优异的物性，同时导热性又优异，从而可以沿纤维增强复合结构体的厚度方向有效传递热量。
在一实施方式中，上述增强纤维和缝合构件可以具有-1×10-6K-1至1×10-6K-1范围的热膨胀系数。特别是，热膨胀系数越低，热量导致的变形可以越少，因此，在温度变化大的环境下，目标可以稳定地维持本来的模样。下文的表1显示碳增强纤维和环氧树脂的热膨胀系数，表2表示用它们制造的碳纤维复合材料的热膨胀系数。
【表1】
热膨胀系数(纤维，环氧树脂) (×10<sup>6</sup>,/°F) (×10<sup>6</sup>,/℃)
聚丙烯腈(PAN)系碳纤维(T50) -0.5 -0.9
沥青系碳纤维(P55) -0.7 -1.26
沥青系碳纤维(P75) -0.75 -1.35
沥青系碳纤维(P120) -0.8 -1.44
环氧树脂(Fiberite 934) 28 50.4
增强环氧树脂(ERL 1962) 24 43.2
氰酸酯(YLA RS3) 31.5 56.7
【表2】
热膨胀系数(复合材料) (×10<sup>6</sup>,/°F) (×10<sup>6</sup>,/℃)
T50/ERL1962 -0.305 -0.549
P55/ERL1962 -0.385 -0.693
P75/ERL1962 -0.501 -0.9018
P120/ERL1962 -0.675 -1.215
P75/934 -0.652 -1.1736
P75/RS3 -0.662 -1.1916
基于表1-2的热膨胀系数值，可以看出，由无碱玻璃(E-glass)构成的玻璃纤维(Glass fiber)的热膨胀系数为4.7～5×10-6(K-1)，在使用由玻璃增强纤维制造的GFRP复合材料的情况下，具有15～25×10-6(K-1)的热膨胀系数，相反，碳纤维为-0.9～-0.5×10-6(K-1)，在使用由碳增强纤维制造的CFRP复合材料的情况下，以-1～1×10-6(K-1)几乎不热膨胀。
另外，上述缝合构件可以包含PAN系碳增强纤维或沥青系碳增强纤维，可以具有-1×10-6K-1至1×10-6K-1范围的热膨胀系数。已知，作为通常的加固材料使用的多壁碳纳米管(MWCNT)的热膨胀系数为16～26×10-6(K-1)，铜的热膨胀系数为17×10-6(K-1)，特别是，与将玻璃纤维、铜丝(wire)、碳纳米管纱线(CNT yarn)等(与CNT的热膨胀系数类似)作为加固材料使用的复合材料相比，根据本申请发明的纤维增强复合结构体可以在热膨胀系数方面更有利。
另一方面，GFRP本身与CFRP相比，热膨胀系数也存在20倍左右的差异，加之，与将热膨胀系数大的铜或碳纳米管纱线(CNT yarn)作为加固材料进行缝合的情况相比，用包含碳增强纤维的碳增强纤维片材和贯通其的缝合构件包含选自PAN系碳增强纤维、沥青系碳增强纤维、以及氮化硼(BN)纤维中的一种以上的情况下，温度导致的长度/体积变化可以非常小，例如可以几乎没有。
因此，本申请发明的纤维增强复合结构体即使在温度变化大的环境(沙漠、大气层外的宇宙等)中，长度或体积的变化也不大，从而寿命长。因此，与现有的技术相比，寿命长，可以容易作为人造卫星结构体或夹心板等的材料适用。
在一实施方式中，上述碳增强纤维包含PAN系碳增强纤维，上述缝合构件包含沥青系碳增强纤维。
因此，以平面方向的碳增强纤维包含PAN系碳增强纤维、厚度方向的缝合构件包含沥青系的组合，与现有的碳增强纤维复合材料相比较，可以构成拉伸强度高且厚度方向的热导率也高的碳增强纤维复合材料。
特别是，根据本发明的纤维复合结构体可以在通过层叠方式构成的增强纤维复合材料层压板中进一步沿厚度方向将由不是碳纳米管(CNT)、纳米碳纤维、导体或金属纤维/线材的最少数千丝束的碳纤维构成的缝合构件利用缝合针来贯通增强纤维片材，通过这种有差异的缝合方法，从而可以沿纤维复合结构体的厚度方向即层叠方向提高热导率。
在一实施方式中，上述缝合构件可以沿增强纤维片材的厚度方向传递热量。
纤维增强复合结构体制造方法
在本发明的一实施方式中，提供一种纤维增强复合结构体制造方法，其中，包括以下步骤：i)层叠复数个增强纤维片材的步骤；ii)将层叠的增强纤维片材中的一个以上的增强纤维片材用缝合构件贯通的步骤；以及iii)使层叠的增强纤维片材成型及固化而形成纤维增强复合结构体的步骤，上述增强纤维片材包含沿一个方向排列的复数个增强纤维。本制造方法中，纤维增强复合结构体的具体特征与上述的内容相同，不再次记载。
在一实施方式中，上述增强纤维片材可以为碳增强纤维片材。
在一实施方式中，上述i)增强纤维片材层叠步骤可以是在相邻的增强纤维片材之间使增强纤维的排列方向彼此不同而层叠的。
在一实施方式中，上述增强纤维片材为预浸料，上述预浸料可以包含沿一个方向排列的复数个增强纤维和浸渗上述增强纤维的高分子树脂。
关于碳增强纤维片材和缝合构件材料的具体特征与上述的内容相同。
在一实施方式中，上述碳增强纤维可以包含PAN系碳增强纤维，上述缝合构件可以包含沥青系碳增强纤维。因此，以平面方向的碳增强纤维包含PAN系碳增强纤维、厚度方向的缝合构件包含沥青系的组合，与现有的碳增强纤维复合材料相比较，可以构成拉伸强度高且厚度方向的热导率也高的碳增强纤维复合材料。
在一实施方式中，上述ii)缝合构件贯通步骤可以包括使包含上述缝合构件的缝合针贯通并去除缝合针的步骤。例如，可以包括使包含上述缝合构件的缝合针贯通，在上述缝合构件贯通着的状态下，只去除缝合针的步骤。这种方法是一种没有将增强纤维再次穿于缝合针的额外过程的简单工序，可以将增强纤维的损伤最小化的同时制造出纤维增强复合结构体。
在一实施方式中，上述缝合针包括内部包含沿长度方向形成的贯通孔的主体、以及配置于上述贯通孔的缝合构件，上述主体的一端可以具有切断倾斜面。
在一实施方式中，上述切断倾斜面可以与主体形成角度，例如，上述切断倾斜面可以与主体形成50°-80°的角度。在50°-80°的角度范围中，既能够保护纤维，同时又能够维持穿过增强纤维片材的程度的锋利度。
另外，上述缝合针的直径可以根据缝合部件的直径而不同，具体而言，缝合针的直径可以为10-20GAUGE或13-16GAUGE。例如，上述缝合针可以为13GAUGE(内径约2.03mm，外径约2.40mm)或16GAUGE(内径约1.27mm外径约1.66mm)。
上述缝合针可以在内部沿长度方向形成的贯通孔中包含缝合构件，因此，缝合针在贯通时可以保护缝合构件。由此，缝合构件就可以与缝合针一同贯通纤维增强复合结构体，缝合构件可以不遭受摩擦导致的损伤。
相反，以往的缝合方法在缝合纤维时使用针和纤维直接通过后切断纤维的方式，在使用这种方式的情况下，在一次缝合之后必须再次使纤维通过穿针，因此，需要将纤维再次穿于针的额外过程。
因此，根据本发明的纤维增强复合结构体制造方法包括使包含缝合构件的缝合针贯通增强纤维片材，从增强纤维片材中去除缝合针的步骤，是一种没有将增强纤维再次穿于缝合针的额外过程的简单工序，将增强纤维的损伤最小化而制造的纤维增强复合结构体可以具有优异的物性。
在一实施方式中，上述成型可以包括利用高压釜(AC)、烘箱成型(例如半预浸料(semi prepreg)、树脂膜渗透(Resin Film Infusion))、长丝缠绕(Filament Winding，FW)、树脂传递模塑(Resin Transfer Molding，RTM)、真空辅助树脂传递模塑(Vacuumassisted RTM，VaRTM)、预浸料压缩成型(Prepreg Compression Molding，PCM)、或者注塑成型的工序。
在一实施方式中，上述成型及固化可以在50-150℃温度下实施10-120分钟。在温度小于50℃的情况下，不发生固化而可能无法完成试样，在温度超过150℃的情况下，可能引起树脂的变色、褐变、树脂的着火、机械物性下降等。此外，在小于10分钟的情况下，未充分发生固化而可能导致物性急剧降低以及未完成试样，在超过120分钟的情况下，可以引起树脂的变色、机械强度下降等现象。
实施例
下面，通过实施例而更详细地说明本发明。这些实施例只是用于例示本发明，不应解释成本发明的范围被这些实施例所限制，这对于本领域技术人员而言是显而易见的。
比较例1：碳纤维增强结构体
将含有PAN系碳纤维的预浸料(USN200A，SK公司)沿着与纤维的方向分别垂直、平行的方向切成横向、纵向8cm的正四边形形状。对于该预浸料片，奇数层旋转0°，偶数层旋转90°，使得相邻的层的纤维的方向彼此垂直，层叠了22层，从而制作了纤维增强结构体。
实施例1：纤维增强复合结构体(1次缝合，PAN系)
将含有PAN系碳纤维的预浸料(USN200A，SK公司)沿着与纤维的方向分别垂直、平行的方向切成横向、纵向8cm的正四边形形状。对于此预浸料片，奇数层旋转0°，偶数层旋转90°，使得相邻的层的纤维的方向彼此垂直，层叠了22层，从而制造了纤维增强结构体。然后，使PAN系碳纤维(T700，TORAY公司)穿过规定粗细的缝合针，用此针对纤维增强结构体中直径19mm的圆内部的1点进行缝合。使贯通的针尖充分向上升高后，将纤维抽出以使纤维成为贯通预浸料的模样(图2c、2d)。将纤维贯通后，注意纤维不再与针一起掉落，将贯通预浸料的针再次向后拔出(图2e)。为了防止插入的纤维脱落，在前后留下富余后进行切割。然后，通过利用真空的预浸料模塑成型工艺，在80℃进行30分钟、在125℃进行90分钟的成型及固化，从而制造了纤维增强复合结构体。
实施例2：纤维增强复合结构体(1次缝合，沥青系)
贯通纤维增强结构体来缝合的碳纤维使用沥青系碳纤维(XN-90-60S，NGF公司)，除此以外，通过与实施例1相同的方法制造了纤维增强复合结构体。
实施例3：纤维增强复合结构体(4次缝合，PAN系)
对纤维增强结构体中直径19mm的圆内部的4点进行缝合，除此以外，通过与实施例1相同的方法制造了纤维增强复合结构体。
实施例4：纤维增强复合结构体(4次缝合，沥青系)
对纤维增强结构体中直径19mm的圆内部的4点进行缝合，除此以外，通过与实施例2相同的方法制造了纤维增强复合结构体。
实施例5：纤维增强复合结构体(7次缝合，沥青系)
对纤维增强结构体中直径19mm的圆内部的7点进行缝合，除此以外，通过与实施例2相同的方法制造了纤维增强复合结构体。
实验例1：热导率分析。
为了掌握比较例1和实施例1-5的纤维增强复合结构体的厚度方向热导率，利用了瞬态平面热源法(Hot disk)热物性测量装置。热导率实验条件如下表3所示。
【表3】
热扩散率(Heat diffusivity)
-样本：圆柱Φ19mm×3-5mm
-测量时间：1-30s
-输入功率：50-250mW
比热(Specific heat)
-样本：圆柱Φ19mm×3-5mm
-测量时间：5-120s
-输入功率：50-250mW
通过本分析，从而掌握了比较例和实施例的纤维增强复合结构体的热扩散率、比热、热导率等热物性。然后，通过测定的比热、热扩散率来计算了热导率，测定的热扩散率和计算的热导率如表4所示。
【表4】
Figure BDA0002424857530000121
热扩散率测定结果，沿厚度方向的热扩散率值与未缝合的比较例1相比，分别增加了实施例1(缝合_1_T)约14.8％、实施例2(缝合_1_XN)约49.9％。如果计算热导率，则沿厚度方向的热导率值与未缝合有碳纤维的比较例1相比，分别增加了实施例1(缝合_1_T)约17.2％、实施例2(缝合_1_XN)约61.5％。与热扩散率的增加率相比，热导率的增加率大是因为乘以各实施例的比热容。虽然看不出线性增加的趋势，但比热容在包含缝合部件时大致显示增加。此外，与实施例1(缝合_1_T)相比，实施例2(缝合_1_XN)的热导率值显示高出约37％的水平。这是由用作缝合构件的碳纤维本身的热导率值的差异导致的。
另外，对4个点进行缝合的实施例3(缝合_4_T)和实施例4(缝合_4_XN)与比较例1(原始)相比，显示为热扩散率的增加率分别为55.4％、46.8％，厚度方向的热导率分别提高70.5％、64.9％。对7个点进行缝合的实施例5(缝合_7_XN)与比较例1(原始)的热扩散率、热导率相比，分别增加107.1％、122.6％，从而显示了所有实施例中最高值的增加率。
PAN系碳纤维作为缝合构件而进入的实施例1(缝合_1_T)和实施例3(缝合_4_T)的热导率值分别为1.172、1.705(W/mK)，可以看到显著上升。可以看到，沥青系碳纤维作为缝合构件而进入的实施例2(缝合_1_XN)、实施例4(缝合_4_XN)、实施例5(缝合_7_XN)的热导率值分别为1.615、1.649、2.226(W/mK)，即使仅进入一个点，热导率与比较例1(原始)相比，也增加61％以上。
在前面说明的本发明的实施例不应解释为限定本发明的技术思想。本发明的保护范围仅通过权利要求书中记载的权利要求来限定，本发明的技术领域中的技术人员能够将本发明的技术思想改良变更为各种形态。因此，这种改良和变更对本领域技术人员而言是显而易见的，也应属于本发明的保护范围。

Claims (17)

1.一种碳纤维增强复合结构体，其中，包含层叠的复数个碳增强纤维片材、以及贯通一个以上碳增强纤维片材的缝合构件，
所述碳增强纤维片材包含沿一个方向排列的复数个增强纤维。
2.根据权利要求1所述的碳纤维增强复合结构体，其中，相邻的碳增强纤维片材的碳增强纤维的排列方向彼此不同。
3.根据权利要求2所述的碳纤维增强复合结构体，其中，相邻的碳增强纤维片材是使碳纤维的排列方向成90°而层叠的。
4.根据权利要求1所述的碳纤维增强复合结构体，其中，所述碳增强纤维片材为预浸料，所述预浸料包含沿一个方向排列的复数个碳增强纤维和浸渗所述碳增强纤维的高分子树脂。
5.根据权利要求1所述的碳纤维增强复合结构体，其中，所述缝合构件包含选自聚丙烯腈系碳增强纤维、沥青系碳增强纤维、以及氮化硼纤维中的一种以上。
6.根据权利要求1所述的碳纤维增强复合结构体，其中，所述碳增强纤维包含聚丙烯腈系碳增强纤维，所述缝合构件包含沥青系碳增强纤维。
7.根据权利要求1所述的碳纤维增强复合结构体，其中，所述碳增强纤维和缝合构件具有-1×10-6K-1至1×10-6K-1范围的热膨胀系数。
8.根据权利要求1所述的碳纤维增强复合结构体，其中，所述缝合构件沿碳增强纤维片材的厚度方向传递热量。
9.一种碳纤维增强复合结构体制造方法，其中，包括以下步骤：
i)层叠复数个碳增强纤维片材的步骤；
ii)将层叠的碳增强纤维片材中的一个以上的碳增强纤维片材用缝合构件贯通的步骤；以及
iii)使层叠的碳增强纤维片材成型及固化而形成碳纤维增强复合结构体的步骤，
所述碳增强纤维片材包含沿一个方向排列的复数个增强纤维。
10.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述i)碳增强纤维片材层叠步骤是在相邻的碳增强纤维片材之间使碳增强纤维的排列方向彼此不同而层叠的。
11.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述碳增强纤维片材为预浸料，所述预浸料包含沿一个方向排列的复数个碳增强纤维和浸渗所述碳增强纤维的高分子树脂。
12.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述碳增强纤维包含聚丙烯腈系碳纤维，所述缝合构件包含沥青系碳增强纤维。
13.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述ii)缝合构件贯通步骤包括使包含所述缝合构件的缝合针贯通并去除缝合针。
14.根据权利要求13所述的碳纤维增强复合结构体制造方法，其中，所述缝合针包括内部包含沿长度方向形成的贯通孔的主体、以及配置于所述贯通孔的缝合构件，所述主体的一端具有切断倾斜面。
15.根据权利要求14所述的碳纤维增强复合结构体制造方法，其中，所述切断倾斜面与主体形成50°-80°的角度。
16.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述成型及固化包括利用高压釜即AC、烘箱成型、长丝缠绕即FW、树脂传递模塑即RTM、真空辅助树脂传递模塑即VaRTM、预浸料压缩成型即PCM、或者注塑成型的工序。
17.根据权利要求9所述的碳纤维增强复合结构体制造方法，其中，所述成型及固化在50-150℃的温度下实施10-120分钟。
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