EP3176295A1 - Fil continu combiné et son procédé de fabrication - Google Patents

Fil continu combiné et son procédé de fabrication Download PDF

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Publication number
EP3176295A1
EP3176295A1 EP15827142.9A EP15827142A EP3176295A1 EP 3176295 A1 EP3176295 A1 EP 3176295A1 EP 15827142 A EP15827142 A EP 15827142A EP 3176295 A1 EP3176295 A1 EP 3176295A1
Authority
EP
European Patent Office
Prior art keywords
fiber material
filament yarn
synthetic fiber
combined filament
reinforcing fiber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP15827142.9A
Other languages
German (de)
English (en)
Other versions
EP3176295A4 (fr
Inventor
Shota KODERA
Yusuke OHE
Susumu Takagi
Kazumasa Kawabe
Keiichi Kondo
Hirofumi IYO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Seiren Co Ltd
Original Assignee
Seiren Co Ltd
Fukui Prefecture
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Seiren Co Ltd, Fukui Prefecture filed Critical Seiren Co Ltd
Publication of EP3176295A1 publication Critical patent/EP3176295A1/fr
Publication of EP3176295A4 publication Critical patent/EP3176295A4/fr
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
    • D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/18—Separating or spreading
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]

Definitions

  • the present invention relates to a combined filament yarn in which a reinforcing fiber material such as a carbon fiber and a synthetic fiber material such as a thermoplastic resin are combined, and to a manufacturing method thereof.
  • the fiber reinforced composite material is obtained by combining a fiber material and a matrix material and is a light-weighted and highly rigid material capable of diversified functional designs and used in a wide variety of fields such as aerospace, transport, civil engineering and construction, and exercise tools.
  • a fiber reinforced plastic (FRP) in which a reinforcing fiber material such as a carbon fiber or a glass fiber is combined with a synthetic resin material such as a thermosetting resin material or a thermoplastic resin material has become mainstream.
  • PTL 1 describes manufacturing a prepreg by overlapping a resin sheet in which a resin is laminated on a mold releasing film, on a fiber body in which the carbon fibers are arranged in one direction and by heating them so as to impregnate the fiber body with a resin.
  • NPL 1 " Trial production and physical characteristic evaluation of thermoplastic carbon fiber reinforced composite material using commingled yarn” by Hiroyuki Hasebe and two others, pp. 11 to 12, Lecture abstracts, Hokuriku Branch, the Textile Machinery Society of Japan
  • Such prior-art combined filament yarns include those in which a sheath yarn is wound around a core yarn by covering, but in such combined filament yarns, the reinforcing fiber material and the synthetic fiber material are separated in two layers, and it is difficult to bring about a uniformly combined state.
  • NPL 1 a carbon fiber and a synthetic fiber made of polyphenylenesulfide (PPS) are overlapped while being fed out at a constant speed, and the both are interlaced by blowing air by an air nozzle to the overlapped portion so as to combine the fibers.
  • PPS polyphenylenesulfide
  • the present invention has an object to provide a combined filament yarn having a favorable quality in which a synthetic fiber material is dispersed in a reinforcing fiber material and combined therewith, and a manufacturing method thereof.
  • a combined filament yarn according to the present invention is a combined filament yarn in which, with a reinforcing fiber material arranged in a predetermined direction, a synthetic fiber material arranged in the same direction as that of the reinforcing fiber material is combined, wherein the synthetic fiber material is bonded to and integrated with the reinforcing fiber material, and the synthetic fiber material is dispersed so that a standard deviation relating to a rate of a sectional area of the synthetic fiber material in a divided region obtained by dividing a section of the combined filament yarn becomes 25 or less.
  • a manufacturing method of a combined filament yarn according to the present invention includes an overlapping process of overlapping a synthetic fiber material on a sheet-state reinforcing fiber material spread and arranged in a predetermined direction in a state where the synthetic fiber material is arranged in the same direction as that of the reinforcing fiber material and dispersed in accordance with density of the reinforcing fiber material, and an integrating process of bonding and integrating the overlapped reinforcing fiber material and synthetic fiber material. Moreover, in the overlapping process, the overlapped reinforcing fiber material and the synthetic fiber material are subjected to spreading processing. Furthermore, a yarn forming process of forming the bonded and integrated reinforcing fiber material and synthetic fiber material into a yarn in another form is provided.
  • the present invention has the constitution as above, a combined filament yarn having a favorable quality in which the synthetic fiber material is dispersed in the reinforcing fiber material and combined therewith can be obtained.
  • a molded product is to be obtained by using the combined filament yarn of the present invention, a high-quality molded product without a void can be obtained even under a relatively mild molding condition.
  • Fig. 1 is an explanatory diagram relating to a process of manufacturing a combined filament yarn according to the present invention.
  • a sheet forming process of forming a reinforcing fiber material and a synthetic fiber material to be raw materials of a combined filament yarn into a sheet state is performed.
  • a fiber bundle is spread and formed into a thin-layer sheet shape.
  • Methods for spreading the reinforcing fiber material include known methods such as a method for spreading the fiber bundle by bringing it into contact with an spreading roller, a vibration roller or the like, a method for spreading the fiber bundle while bending the fiber bundle by causing the fiber bundle to feed so as to cross a flow of a fluid, and a method for spreading the fiber bundle combining them.
  • the method for spreading the fiber bundle while bending the fiber bundle by using the fluid can uniformly spread the fiber bundle without damaging the reinforcing fiber, it is suitable as the method for spreading the reinforcing fiber material. Moreover, by arranging a plurality of fiber bundles in parallel in a width direction and by applying the spreading processing to them at the same time, it is possible to easily form a wide sheet shape.
  • the synthetic fiber material those in a state of a fiber bundle can be formed into a thin-layer sheet shape by warping processing using a warping machine or the spreading processing similar to the method for spreading the reinforcing fiber material.
  • the fiber material is to be manufactured by spinning from a synthetic resin material to be a raw material, a thin-layer sheet-state synthetic fiber material can be obtained by spinning in a state where the fiber material is aligned in a sheet state.
  • the reinforcing fiber materials include inorganic fibers, organic fibers and the like with high intensity/high modulus of elasticity used in FRP such as a carbon fiber, a glass fiber, a ceramic fiber, an aramid fiber, a PBO (polypara-phenylenebenzobisoxazole) fiber, and a metal fiber, for example.
  • a plurality of the fiber bundles in each of which these fibers are bundled may be combined.
  • fineness is not particularly limited.
  • those to be base (matrix) resins such as polypropylene, polyethylene, polystyrene, polyamide (nylon 6, nylon 66, nylon 12 and the like), polyacetal, polycarbonate, acrylonitrile-butadiene-styrene copolymer (ABS), polyethylene terephthalate, polybutylene terephthalate, LPC (liquid crystal polyester), polyimide, polyether imide, polyether sulfone, polyphenylene sulfide, polyether ketone, and polyetheretherketone are used.
  • two kinds or more of these thermoplastic resins may be mixed so as to form a polymer alloy and used as the base (matrix) resin.
  • a composite fiber material having a melting point on a surface portion lower than that on a center portion can be also used in order to improve adhesiveness with the reinforcing fiber material in an integrating process which will be described later.
  • a composite fiber material having a core-sheath structure in which a synthetic resin material having a high melting point is used as a core portion and a synthetic resin material having a low melting point is used as a sheath portion can be cited.
  • a use amount of the synthetic fiber material may be set in accordance with a use amount of the reinforcing fiber material and can be set on the basis of a volume fraction of fiber (hereinafter abbreviated as a "Vf value") of the fiber reinforced composite material using a combined filament yarn.
  • Vf value volume fraction of fiber
  • the fineness of the synthetic fiber material is preferably such that the synthetic fiber material can easily enter between the reinforcing fibers and has durability against tension applied when being handled as the combined filament yarn.
  • Fig. 2 is an explanatory diagram relating to the overlapping process and the integrating process.
  • the sheet-state reinforcing fiber material T and the sheet-state synthetic fiber material S are fed in parallel in a state arranged in a predetermined direction and passed between pressure-contact rolls R so as to be set in a state in which the sheet-state synthetic fiber material is brought into pressure-contact and overlapped with one side of the sheet-state reinforcing fiber material.
  • the synthetic fiber material S is arranged through adjustment so that it is dispersed in accordance with density of the sheet-state reinforcing fiber material T.
  • the reinforcing fiber material T is a thin layer and has low density
  • a plurality of the synthetic fiber materials S is arranged at a predetermined interval and overlapped in accordance with the density.
  • the reinforcing fiber material T may be overlapped on both sides of the synthetic fiber material S.
  • a spreading mechanism K is arranged on a downstream side in a feeding direction of the pressure-contact rolls R, and in the spreading mechanism K, an air flow is made to cross the reinforcing fiber material T and the synthetic fiber material S in the overlapped state so as to bend and spread them while feeding them.
  • the spreading mechanism K may be a mechanism in which a vibration roller and the like are combined.
  • a tension applied to the reinforcing fiber material T and the synthetic fiber material S is fluctuated, but if the synthetic fiber material S is more expanded/contracted as compared with the reinforcing fiber material T, by arranging the synthetic fiber material S on the downstream side of a flow of the air flow, fibers of the synthetic fiber material S are expanded/contracted during the spreading processing and easily enter between the reinforcing fibers.
  • the synthetic fiber material can be dispersed and overlapped in accordance with the density of the spread reinforcing fiber material, fiber mixing in a more uniform state is made possible.
  • the synthetic fiber material can be dispersed in advance in accordance with processing of a yarn forming process which will be described later, and the synthetic fiber material is overlapped so that a combined state of the combined filament yarn to be manufactured in the end becomes uniform.
  • the integrating process of integrating the reinforcing fiber material and the synthetic fiber material in the overlapped state is performed.
  • the synthetic fiber material S is provisionally bonded and integrated.
  • the synthetic fiber material S is to be provisionally bonded, by performing pressure-contact by the heating rolls H, the synthetic fiber material S is partially melted and thermally fused with the reinforcing fiber material T, but the synthetic fiber material S is bonded still in a state where its fiber form is maintained.
  • the sheath portion is thermally fused with the reinforcing fiber material T and they can be integrated while maintaining the fiber form.
  • the synthetic fiber material By provisionally bonding the synthetic fiber material to the reinforcing fiber material for integration, the spread reinforcing fiber material does not get loose, whereby handling thereof as a combined filament yarn is facilitated. Moreover, since the reinforcing fiber material and the synthetic fiber material are integrated in the state maintaining the fiber form, tension strength or drape properties can be sufficiently provided in weaving using the combined filament yarn.
  • the synthetic fiber material when the synthetic fiber material is to be provisionally bonded to the reinforcing fiber material, the synthetic fiber material may be bonded entirely or partially as necessary, and a bonded spot may be set to a dot shape, a line shape or a band shape, for example, and it may be set as appropriate in accordance with an application of the combined filament yarn.
  • Figs. 3(a) to 3(d) are schematic sectional diagrams of the combined filament yarn.
  • Fig. 3(a) illustrates a sectional diagram of the combined filament yarn obtained by twisting the integrated reinforcing fiber material and synthetic fiber material by a known twisting device.
  • the integrated reinforcing fiber material and synthetic fiber material are formed into a sheet shape and are wound in a width direction by twisting in processing and thus, a state where the synthetic fiber material is dispersed to a center part of the combined filament yarn is brought about and more uniform combined filament yarn can be obtained.
  • Fig. 3(b) illustrates a sectional diagram of the combined filament yarn obtained by folding the integrated reinforcing fiber material and synthetic fiber material plural times so that a folding line is obtained in a yarn length direction. In this case, a state where the reinforcing fiber material and the synthetic fiber material are laminated alternately is brought about, and a more uniform combined filament yarn in which the synthetic fiber material is dispersed to the center part can be obtained.
  • a method of folding includes folding as if winding or staggered folding, and folding only needs to be performed so that the reinforcing fiber material and the synthetic fiber material are alternately laminated.
  • Fig. 3(c) illustrates a sectional diagram of the combined filament yarn obtained by overlapping a plurality of integrated reinforcing fiber materials and synthetic fiber materials. In this case, too, the reinforcing fiber material and the synthetic fiber material are in the alternately laminated state, whereby the synthetic fiber material is dispersed to the center part, and a more uniform combined filament yarn can be obtained.
  • Fig. 3(d) illustrates a sectional diagram of a combined filament yarn obtained by slitting the integrated reinforcing fiber material and synthetic fiber material in the yarn length direction.
  • a combined filament yarn which is combined more uniformly can be manufactured.
  • Uniformity of a combined state of the obtained combined filament yarn can be checked by quantitatively analyzing a dispersed state of the synthetic fiber material in a section in a direction orthogonal to the yarn length direction of the combined filament yarn. For example, by dividing the section into a plurality of divided regions, by calculating a rate of a sectional area of the synthetic fiber material in each of the divided regions, and by checking a standard deviation relating to the calculated rate of each region, the dispersed state can be quantitatively analyzed.
  • the standard deviation ⁇ when molding is performed by hot press or the like using the combined filament yarn, in order for the synthetic fiber material to melt and penetrate between the reinforcing fiber materials to be filled in a state without a void, the standard deviation ⁇ needs to be set to 25 or less.
  • Conditions under which molding is performed by hot press by using the combined filament yarn according to the present invention can be set to a heating temperature of 260 to 320°C, a pressure of 0.1 to 3.0 MPa, and processing time of 3 to 20 minutes.
  • the pressure of 10 MPa or more and processing time of 30 minutes or more are needed.
  • the combined filament yarn was manufactured by using the following materials:
  • the carbon fiber was subjected to the spreading processing to a width of 100 mm by a spreading method by an air flow described in Japanese Patent No. 3064019 .
  • Density of the obtained sheet-state carbon fiber was 150 fibers/mm.
  • the composite fiber was subjected to warping processing to a width of 100 mm by using a known warping machine.
  • the density of the obtained sheet-sate composite fiber was 10 fibers/mm.
  • the carbon fiber and the composite fiber formed having a sheet shape were overlapped while being fed and then, subjected to the spreading processing similar to the spreading method of the carbon fiber so as to form an overlapped sheet material having a width of 100 mm.
  • the formed overlapped sheet material was passed between the heating rolls (170°C) so that the composite fiber is provisionally bonded to and integrated with the carbon fiber.
  • the obtained provisionally bonded sheet material was folded four times along a folding line in the yarn length direction, and the combined filament yarn laminated in 16 layers was manufactured.
  • Fig. 4 is a photographed image relating to the section of the combined filament yarn.
  • the photographed image of the section of the combined filament yarn was processed, and a dispersed state of the area of the composite fiber was evaluated.
  • commercial image-processing software by Olympus Corporation, Stream Essential
  • a region for analysis was defined by drawing a rectangle circumscribed by the section of the combined filament yarn, and the defined rectangular region was equally divided into three parts laterally and vertically, respectively, that is, nine divided regions were set. In Fig. 4 , the divided regions are indicated by white straight lines.
  • An outline was drawn by following an outer shape of the combined filament yarn for each of the divided regions, and an area S1 of the combined filament yarn surrounded by the drawn outline and a border line of the divided region was calculated. Subsequently, an area S2 of the composite fiber surrounded by drawing a surrounding line surrounding only the composite fiber was calculated. In Fig. 4 , the outline and the surrounding line are indicated by white curves.
  • Example 2 The materials similar to those in Example 1 were used, and the sheet forming process to the integrating process were performed similarly to Example 1.
  • the obtained provisionally bonded sheet material was twisted at 100 times/m by the known twisting device so as to manufacture a combined filament yarn.
  • a section of the manufactured combined filament yarn was photographed similarly to Example 1.
  • Fig. 5 is a photographed image relating to the section of the combined filament yarn.
  • image processing was applied to the section image similarly to Example 1, and the standard deviation was calculated.
  • the standard deviation ⁇ was 11.5.
  • Example 2 The materials similar to those in Example 1 were used, and the sheet forming process to the integrating process were performed similarly to Example 1.
  • the obtained provisionally bonded sheet material was wound spirally in the width direction so as to manufacture the combined filament yarn.
  • a section of the manufactured combined filament yarn was photographed similarly to Example 1.
  • image processing was applied to the section image similarly to Example 1, and the standard deviation was calculated.
  • the standard deviation ⁇ was 15.2.
  • Example 2 The materials similar to those in Example 1 were used, and processes from the sheet forming process to the integrating process were performed similarly to Example 1.
  • the obtained provisionally bonded sheet material was slit in the yarn length direction by a known slitter to a width of 2 mm so as to manufacture the combined filament yarn.
  • a section of the manufactured combined filament yarn was photographed similarly to Example 1.
  • image processing was applied to the section image similarly to Example 1, and the standard deviation was calculated.
  • the standard deviation ⁇ was 19.2.
  • Polyester fiber (by KB Seiren, Ltd.; Bellcouple) 280T/16f: 30
  • the polyester fibers were divided into two fiber bundles, each having 15 fibers, and double covering processing was applied with the two fiber bundles by a covering device around the carbon fiber so as to manufacture the combined filament yarn.
  • the number of windings of the fiber bundle was set to 200 times/m.
  • permeability of the composite fiber by hot press was evaluated by using the combined filament yarn obtained in Example 1.
  • the combined filament yarn was set on a hot press device (by Imoto Machinery Co., Ltd.; IMC-180C model), setting was made at the heating temperature of 300°C and a pressurizing force of 0.14 MPa, and hot-press processing was performed for 5 minutes.
  • the combined filament yarn was molded into a plate-shaped body having a width of approximately 4.5 mm and a thickness of approximately 0.4 mm. The molded plate-shaped body was cut off in a thickness direction, and the section was observed by an electron microscope and then, a resin was filled between the carbon fibers revealed to the section, and no void was observed.
  • Example 2 The combined filament yarn obtained in Example 2 was subjected to hot-press processing similarly to Example 5 and molded into a plate shaped body.
  • the molded plate-shaped body was cut off in a thickness direction, and the section was observed by an electron microscope and then, a resin was filled between the carbon fibers revealed to the section, and no void was observed.
  • the combined filament yarn obtained in Comparative Example 1 was subjected to hot-press processing similarly to Example 5 and molded into a plate shaped body.
  • the molded plate-shaped body was cut off in a thickness direction, and the section was observed by an electron microscope and then, a void into which the resin did not penetrate between the carbon fibers revealed to the section was observed.
  • the hot-press processing was performed similarly to Example 5 and a plate-shaped body was molded except that the heating processing temperature was set to 280°C and the pressurizing force to 1.29 MPa.
  • the molded plate-shaped body was cut off in a thickness direction, and the section was observed by an electron microscope and then, a resin was filled between the carbon fibers revealed to the section, and no void was observed.
  • Carbon fibers by Mitsubishi Rayon Co. Ltd.; 50R15L were arranged, and a polyethylene terephthalate film (by Fujimori Kogyo Co., Ltd.; 75-NT2-AS) was overlapped thereon, and the hot-press processing was applied under the condition similar to Example 7 so as to mold a plate-shaped body.
  • the molded plate-shaped body was cut off in a thickness direction, and the section was observed by an electron microscope and then, a void into which the resin did not penetrate between the carbon fibers revealed to the section was observed.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Reinforced Plastic Materials (AREA)
EP15827142.9A 2014-07-30 2015-07-21 Fil continu combiné et son procédé de fabrication Withdrawn EP3176295A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2014155595 2014-07-30
PCT/JP2015/070672 WO2016017469A1 (fr) 2014-07-30 2015-07-21 Fil continu combiné et son procédé de fabrication

Publications (2)

Publication Number Publication Date
EP3176295A1 true EP3176295A1 (fr) 2017-06-07
EP3176295A4 EP3176295A4 (fr) 2018-04-25

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP15827142.9A Withdrawn EP3176295A4 (fr) 2014-07-30 2015-07-21 Fil continu combiné et son procédé de fabrication

Country Status (4)

Country Link
EP (1) EP3176295A4 (fr)
JP (1) JP6682084B2 (fr)
CN (1) CN106414822B (fr)
WO (1) WO2016017469A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019231633A1 (fr) * 2018-05-31 2019-12-05 Hexcel Corporation Augmentation du nombre de filaments de câbles de fibres de carbone

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Publication number Priority date Publication date Assignee Title
GB201604047D0 (en) 2016-03-09 2016-04-20 Coats Ltd J & P Thread
JP6867644B2 (ja) * 2017-03-31 2021-05-12 株式会社サンライン 糸の製造方法および釣り用糸
CN110658013A (zh) * 2018-06-29 2020-01-07 北新集团建材股份有限公司 一种评价玻璃纤维在纸面石膏板中的分散性的方法

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JPH01280031A (ja) * 1988-05-06 1989-11-10 Teijin Ltd 複合繊維の製造方法
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JP3345661B2 (ja) * 1992-11-17 2002-11-18 東洋紡績株式会社 熱可塑性コンポジット用ヤーン
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019231633A1 (fr) * 2018-05-31 2019-12-05 Hexcel Corporation Augmentation du nombre de filaments de câbles de fibres de carbone
US10604870B2 (en) 2018-05-31 2020-03-31 Hexcel Corporation Increasing the filament count of carbon fiber tows

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Publication number Publication date
JP6682084B2 (ja) 2020-04-15
CN106414822B (zh) 2019-11-26
EP3176295A4 (fr) 2018-04-25
CN106414822A (zh) 2017-02-15
WO2016017469A1 (fr) 2016-02-04
JPWO2016017469A1 (ja) 2017-04-27

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