JP2005239843A - Prepreg excellent in homogeneity and surface smoothness, and its manufacturing method - Google Patents
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- 229920005989 resin Polymers 0.000 claims abstract description 62
- 239000011347 resin Substances 0.000 claims abstract description 62
- 239000000463 material Substances 0.000 claims abstract description 55
- 239000012783 reinforcing fiber Substances 0.000 claims abstract description 52
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 52
- 239000000843 powder Substances 0.000 claims abstract description 38
- 239000000725 suspension Substances 0.000 claims abstract description 24
- 238000010438 heat treatment Methods 0.000 claims abstract description 15
- 239000003960 organic solvent Substances 0.000 claims abstract description 11
- 239000012046 mixed solvent Substances 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 150000001298 alcohols Chemical class 0.000 claims abstract description 6
- 150000002576 ketones Chemical class 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 25
- 239000011800 void material Substances 0.000 claims description 14
- 238000009826 distribution Methods 0.000 claims description 8
- 239000004760 aramid Substances 0.000 claims description 5
- 238000000790 scattering method Methods 0.000 claims description 5
- 125000003118 aryl group Chemical group 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 230000001186 cumulative effect Effects 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- -1 polypropylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 2
- 239000004962 Polyamide-imide Substances 0.000 claims description 2
- 239000004695 Polyether sulfone Substances 0.000 claims description 2
- 239000004697 Polyetherimide Substances 0.000 claims description 2
- 229920003235 aromatic polyamide Polymers 0.000 claims description 2
- 230000009477 glass transition Effects 0.000 claims description 2
- 229920001643 poly(ether ketone) Polymers 0.000 claims description 2
- 229920002492 poly(sulfone) Polymers 0.000 claims description 2
- 229920002312 polyamide-imide Polymers 0.000 claims description 2
- 229920000412 polyarylene Polymers 0.000 claims description 2
- 239000004417 polycarbonate Substances 0.000 claims description 2
- 229920000515 polycarbonate Polymers 0.000 claims description 2
- 229920006393 polyether sulfone Polymers 0.000 claims description 2
- 229920002530 polyetherether ketone Polymers 0.000 claims description 2
- 229920001601 polyetherimide Polymers 0.000 claims description 2
- 229920006259 thermoplastic polyimide Polymers 0.000 claims description 2
- 239000002657 fibrous material Substances 0.000 abstract description 18
- 150000008282 halocarbons Chemical class 0.000 abstract description 2
- 238000003825 pressing Methods 0.000 abstract description 2
- 238000007598 dipping method Methods 0.000 abstract 1
- 239000000835 fiber Substances 0.000 description 21
- 238000000034 method Methods 0.000 description 16
- 229920000049 Carbon (fiber) Polymers 0.000 description 15
- 239000004917 carbon fiber Substances 0.000 description 15
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 12
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 10
- 239000002612 dispersion medium Substances 0.000 description 7
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 6
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 6
- 239000002131 composite material Substances 0.000 description 6
- 238000005470 impregnation Methods 0.000 description 6
- 239000002904 solvent Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 229920006231 aramid fiber Polymers 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 229920001721 polyimide Polymers 0.000 description 3
- 239000009719 polyimide resin Substances 0.000 description 3
- 239000004734 Polyphenylene sulfide Substances 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000012784 inorganic fiber Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229920000069 polyphenylene sulfide Polymers 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- SCYULBFZEHDVBN-UHFFFAOYSA-N 1,1-Dichloroethane Chemical compound CC(Cl)Cl SCYULBFZEHDVBN-UHFFFAOYSA-N 0.000 description 1
- XNWFRZJHXBZDAG-UHFFFAOYSA-N 2-METHOXYETHANOL Chemical compound COCCO XNWFRZJHXBZDAG-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 229920000690 Tyvek Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005868 electrolysis reaction Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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Abstract
Description
本発明は、シート状の強化繊維材料とこれに含浸せしめられた熱可塑性樹脂とからなる、均一性と表面平滑性に優れたプリプレグとその製造法に関する。 The present invention relates to a prepreg comprising a sheet-like reinforcing fiber material and a thermoplastic resin impregnated therein and excellent in uniformity and surface smoothness, and a method for producing the same.
近年、炭素繊維、ガラス繊維、アラミド繊維等の強化繊維材料は、各種のマトリックス樹脂と複合化され、得られる強化繊維複合材料は種々の分野・用途に広く利用されるようになってきた。そして、高度の機械的特性や耐熱性等を要求される航空・宇宙分野や、一般産業分野では、従来、マトリックス樹脂として、不飽和ポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂が使用されてきた。しかし、特に航空・宇宙分野では、これらのマトリックス樹脂は、脆く、耐衝撃性に劣るという欠点を有するため、その改善が求められてきた。また、熱硬化性樹脂の場合、これをプリプリグとしたとき、樹脂のライフ等によるプリプレグの保存管理上の問題点や、成形時間が長く生産性が低い等の問題もあった。 In recent years, reinforcing fiber materials such as carbon fibers, glass fibers, and aramid fibers have been combined with various matrix resins, and the resulting reinforcing fiber composite materials have been widely used in various fields and applications. And in the aerospace field and general industrial fields where high mechanical properties and heat resistance are required, conventionally, thermosetting resins such as unsaturated polyester resin, epoxy resin, and polyimide resin have been used as matrix resins. It has been. However, especially in the aerospace field, these matrix resins have the drawbacks of being brittle and inferior in impact resistance, and therefore, improvement has been demanded. Further, in the case of a thermosetting resin, when this is used as a prepreg, there are problems in the storage management of the prepreg due to the life of the resin, and problems such as a long molding time and low productivity.
これに対して、熱可塑性樹脂プリプレグの場合は、複合材料としたときの耐衝撃性が優れ、プリプレグの保存管理が容易で、かつ成形時間が短く、成形コスト低減の可能性もある。熱可塑性樹脂プリプレグの製造法としては、従来、例えば、フイルム状の樹脂を加熱溶融して強化繊維材料に含浸させる方法（溶融含浸法）、粉末状の樹脂を流動床法や懸濁法によって強化繊維材料に塗布・融着させる方法（パウダー法）、樹脂を溶液化し、強化繊維材料に含浸後溶媒を除去する方法（溶液含浸法）が知られている。しかしながら、溶融含浸法は、樹脂の溶融粘度が高いため繊維材料の内部にまで均一に樹脂を含浸させるのが困難であり、パウダー法では、樹脂の付着量を調整するのが難しく、溶液含浸法では、使用できる樹脂や溶媒の種類が制限されるという問題点・欠点があった。 On the other hand, in the case of a thermoplastic resin prepreg, the impact resistance when it is made into a composite material is excellent, the storage management of the prepreg is easy, the molding time is short, and the molding cost may be reduced. Conventional methods for producing a thermoplastic resin prepreg include, for example, a method in which a film-like resin is heated and melted to impregnate a reinforcing fiber material (melting impregnation method), and a powdery resin is reinforced by a fluidized bed method or a suspension method. A method of applying and fusing to a fiber material (powder method) and a method of making a resin into a solution and removing the solvent after impregnating the reinforcing fiber material (solution impregnation method) are known. However, the melt impregnation method has a high melt viscosity of the resin, so it is difficult to uniformly impregnate the resin into the inside of the fiber material. In the powder method, it is difficult to adjust the amount of the resin adhered, and the solution impregnation method However, there are problems and drawbacks in that the types of resins and solvents that can be used are limited.
従来技術を改良したプリプレグの製造方法として、熱可塑性樹脂の粉末をアルコール等の有機溶媒又は有機溶媒と水との混合溶媒に分散させてサスペンジョンとし、かかるサスペンジョンに炭素繊維のストランド又はシートを浸漬し、樹脂粉末をストランド又はシートに付着させた後加熱して、樹脂を溶融させて熱可塑性樹脂と炭素繊維のストランド又はシートを一体化させる方法が提案されている。この方法によると、樹脂が比較的均一に含浸したプリプレグ（含浸樹脂量のバラツキ値が４．２〜５．０）が得られること、更にサスペンジョンに通電処理を行う方法を組合わせると、バラツキ値が２．８〜３．８のものも得られたことが例示されている。
しかしながら、最近の特に航空・宇宙分野の材料としては、より一層均一性等に優れたプリプレグが求められるようになっており、しかもその製造法も出来るだけシンプルなものである必要がある。 However, as a recent material in the field of aerospace, in particular, a prepreg having further excellent uniformity and the like has been demanded, and its manufacturing method needs to be as simple as possible.
本発明は、シート状の強化繊維材料とこれに含浸せしめられた熱可塑性樹脂とからなる、ボイドが少なくかつ厚みのバラツキも少ない、均一性と表面平滑性に優れたプリプレグを提供することを目的とするものである。 An object of the present invention is to provide a prepreg composed of a sheet-like reinforcing fiber material and a thermoplastic resin impregnated therein, having less voids and less variation in thickness, and having excellent uniformity and surface smoothness. It is what.
本発明の目的は、シート状の強化繊維材料とこれに含浸せしめられた熱可塑性樹脂とからなるプリプレグであって、該プリプレグのボイド率が１％以下で、厚みのバラツキ値が５％以下であることを特徴とする均一性と表面平滑性に優れたプリプレグによって達成される。なお、ここで含浸とは、強化繊維材料に付着した樹脂粉末が、一旦融解し、繊維間又は繊維表面に樹脂が実質的に連続層として存在する状態をいう。 An object of the present invention is a prepreg comprising a sheet-like reinforcing fiber material and a thermoplastic resin impregnated therein, wherein the prepreg has a void ratio of 1% or less and a thickness variation value of 5% or less. This is achieved by a prepreg having excellent uniformity and surface smoothness. Here, the impregnation means a state in which the resin powder attached to the reinforcing fiber material is once melted, and the resin is present as a continuous layer between the fibers or on the fiber surface.
そしてかかるプリプレグは、シート状の強化繊維材料に熱可塑性樹脂を含浸させてプリプレグを製造するに当たり、熱可塑性樹脂粉末を、アルコール類、ケトン類、ハロゲン化炭素類から選ばれた１種若しくは２種以上の有機溶媒又はかかる有機溶媒と水との混合溶媒に分散させたサスペンジョンに、シート状の強化繊維材料を浸漬させて、樹脂粉末をこの強化繊維材料に付着せしめ、次いで樹脂粉末が付着した強化繊維材料を170〜390℃に加熱して樹脂粉末を溶融させ、引き続いて上下一対の加熱・加圧ローラーを用いてローラー圧力３〜１０Ｋｇ／ｃｍ、ローラー温度（Ｔｇ＋１５）〜（Ｔｇ＋１００）℃で加熱して樹脂を含浸させ、シート状の強化繊維材料と熱可塑性樹脂を一体化させるという方法で得られる。 Such a prepreg is produced by impregnating a sheet-like reinforcing fiber material with a thermoplastic resin to produce a prepreg, and the thermoplastic resin powder is selected from one or two selected from alcohols, ketones and halogenated carbons. A sheet-like reinforcing fiber material is immersed in a suspension dispersed in the above organic solvent or a mixed solvent of such an organic solvent and water, and the resin powder is adhered to the reinforcing fiber material, and then the resin powder is adhered. The fiber material is heated to 170 to 390 ° C. to melt the resin powder, and subsequently heated at a roller pressure of 3 to 10 kg / cm and a roller temperature (Tg + 15) to (Tg + 100) ° C. using a pair of upper and lower heating / pressure rollers. Then, the resin is impregnated and the sheet-like reinforcing fiber material and the thermoplastic resin are integrated.
本発明によれば、強化繊維材料に熱可塑性樹脂を均一にかつ内部にまで含浸させると共に、表面を非常に平滑に仕上げることができる。そして、得られたプリプレグは、これを用いて色々な用途の強化繊維複合材料に成形でき、プリプレグの均一性が高いが故に、得られた複合材料の機械的特性や耐熱性等の物性が非常に優れたものとなる。 According to the present invention, the reinforcing fiber material can be uniformly impregnated with the thermoplastic resin to the inside, and the surface can be finished very smoothly. The obtained prepreg can be molded into a reinforced fiber composite material for various uses by using this, and the physical properties such as mechanical properties and heat resistance of the obtained composite material are extremely high because the prepreg has high uniformity. It will be excellent.
本発明は、シート状の強化繊維材料とこれに含浸せしめられた熱可塑性樹脂とからなるプリプレグであって、プリプレグのボイド率が１％以下で、厚みのバラツキ値が５％以下であることを特徴とする均一性と表面平滑性に優れたプリプレグであるが、好ましくは、プリプレグ中の熱可塑性樹脂の含有率が１０〜７０重量％、より好ましくは２０〜５０重量％のものである。 The present invention is a prepreg comprising a sheet-like reinforcing fiber material and a thermoplastic resin impregnated therein, wherein the prepreg has a void ratio of 1% or less and a thickness variation value of 5% or less. Although it is a prepreg having excellent uniformity and surface smoothness, the content of the thermoplastic resin in the prepreg is preferably 10 to 70% by weight, more preferably 20 to 50% by weight.
本発明において、シート状の強化繊維材料とは、繊維材料を一方向にシート状に引き揃えたもの、これらを例えば直交に積層したもの、繊維材料を織物や不織布等の布帛に成形したもの、編組等のストランド状のものを全て含む。強化繊維材料としては、無機繊維、有機繊維、金属繊維又はそれらの混合からなる繊維材料がある。具体的には、無機繊維としては、炭素繊維、黒鉛繊維、炭化珪素繊維、アルミナ繊維、タングステンカーバイド繊維、ボロン繊維、ガラス繊維を挙げることが出来る。有機繊維としては、アラミド繊維、高密度ポリエチレン繊維、ポリアミド繊維、ポリエステル繊維が挙げられる。好ましいのは、炭素繊維とアラミド繊維である。 In the present invention, the sheet-like reinforcing fiber material is one in which the fiber materials are arranged in a sheet shape in one direction, these are laminated, for example, orthogonally, and the fiber material is formed into a fabric such as a woven fabric or a nonwoven fabric. Includes all strands such as braids. As the reinforcing fiber material, there are fiber materials made of inorganic fibers, organic fibers, metal fibers, or a mixture thereof. Specifically, examples of the inorganic fiber include carbon fiber, graphite fiber, silicon carbide fiber, alumina fiber, tungsten carbide fiber, boron fiber, and glass fiber. Examples of organic fibers include aramid fibers, high density polyethylene fibers, polyamide fibers, and polyester fibers. Preference is given to carbon fibers and aramid fibers.
本発明において用いられる熱可塑性樹脂は、特に制限されないが、融点又はガラス転移温度が、１５０℃以上の結晶性又は非晶性の熱可塑性樹脂が好ましい。好ましい樹脂の具体例は、ポリプロピレン、ポリスルホン、ポリエーテルスルホン、ポリエーテルケトン、ポリエーテルエーテルケトン、芳香族ポリアミド、芳香族ポリエステル、芳香族ポリカーボネート、ポリエーテルイミド、ポリアリーレンオキシド、熱可塑性ポリイミド、ポリアミドイミドである。これらの樹脂は、２種以上併用しても良い。 The thermoplastic resin used in the present invention is not particularly limited, but a crystalline or amorphous thermoplastic resin having a melting point or glass transition temperature of 150 ° C. or higher is preferable. Specific examples of preferred resins are polypropylene, polysulfone, polyethersulfone, polyetherketone, polyetheretherketone, aromatic polyamide, aromatic polyester, aromatic polycarbonate, polyetherimide, polyarylene oxide, thermoplastic polyimide, polyamideimide It is. Two or more of these resins may be used in combination.
本発明において樹脂粉末は、強化繊維材料への良好な付着（繊維間あるいは繊維表面に樹脂粉末が保持された状態）を考慮すると、樹脂粉末の粒子径は５０μｍ以下で、取扱性の点からは１μｍを下回らないのが良く、平均粒子径が５〜２０μｍの範囲のものが好ましい。 In the present invention, the resin powder has a particle diameter of 50 μm or less in consideration of good adhesion to the reinforcing fiber material (a state in which the resin powder is held between fibers or on the fiber surface). It is preferable that the average particle diameter is not less than 1 μm and the average particle diameter is 5 to 20 μm.
また、本発明において用いる熱可塑性樹脂粉末が、レーザー回折散乱法により測定した粒度分布が下記（１）と（２）と（３）の条件を満足する熱可塑性樹脂粉末である場合には、サスペンジョン浴の安定性に優れ、得られるプリプレグの均一性もより一層優れているので好ましい。
（１）４μｍ≦１０％での粒径
（２）８μｍ≦５０％での粒径≦１５μｍ
（３）９０％での粒径≦２０μｍ
（但し、粒径とは、レーザー回折散乱法により粒度分布を測定した場合において、累積グラフにおける各体積％での粒径を意味する。）
ここで、粒度分布とは、マイクロトラック ＦＲＡ（日機装社製）を用いて、レーザー回折散乱法により測定したもので、得られた粒度分布の累積グラフにおける１０％、５０％、９０％の各体積％での粒径（μｍ）を求めて粒度分布としたものである。
In the case where the thermoplastic resin powder used in the present invention is a thermoplastic resin powder whose particle size distribution measured by a laser diffraction scattering method satisfies the following conditions (1), (2) and (3), This is preferable because the bath stability is excellent and the uniformity of the prepreg obtained is further excellent.
(1) Particle size at 4 μm ≦ 10% (2) Particle size at 8 μm ≦ 50% ≦ 15 μm
(3) Particle size at 90% ≦ 20 μm
(However, the particle size means the particle size at each volume% in the cumulative graph when the particle size distribution is measured by the laser diffraction scattering method.)
Here, the particle size distribution is measured by a laser diffraction scattering method using Microtrac FRA (manufactured by Nikkiso Co., Ltd.), and each volume of 10%, 50% and 90% in the cumulative graph of the obtained particle size distribution % Particle size (μm) is obtained to obtain a particle size distribution.
本発明の均一性に優れたプリプレグは以下に述べる方法によって製造され。即ち、シート状の強化繊維材料に熱可塑性樹脂を含浸させてプリプレグを製造するに当たり、熱可塑性樹脂粉末を、アルコール類、ケトン類、ハロゲン化炭素類から選ばれた１種若しくは２種以上の有機溶媒又はかかる有機溶媒と水との混合溶媒に分散させたサスペンジョンに、シート状の強化繊維材料を浸漬させて、樹脂粉末をこの強化繊維材料に付着せしめ、次いで樹脂粉末が付着した強化繊維材料を170〜390℃に加熱して樹脂粉末を溶融させ、引き続いて上下一対の加熱・加圧ローラーを用いてローラー圧力３〜１０Ｋｇ／ｃｍ（計算線圧）、ローラー温度（Ｔｇ＋１５）〜（Ｔｇ＋１００）℃に加熱して樹脂を含浸させ、シート状の強化繊維材料と熱可塑性樹脂を一体化させてプリプレグが製造される。 The prepreg excellent in uniformity of the present invention is produced by the method described below. That is, in the production of a prepreg by impregnating a sheet-like reinforcing fiber material with a thermoplastic resin, the thermoplastic resin powder is made of one or more organic compounds selected from alcohols, ketones and halogenated carbons. A sheet-like reinforcing fiber material is immersed in a suspension dispersed in a solvent or a mixed solvent of such an organic solvent and water so that the resin powder adheres to the reinforcing fiber material, and then the reinforcing fiber material to which the resin powder adheres is obtained. Heat to 170 to 390 ° C. to melt the resin powder, and then using a pair of upper and lower heating / pressure rollers, roller pressure 3 to 10 kg / cm (calculated linear pressure), roller temperature (Tg + 15) to (Tg + 100) ° C. Is heated to impregnate the resin, and the sheet-like reinforcing fiber material and the thermoplastic resin are integrated to produce a prepreg.
本発明の製造法の一例を、図１を参照しながら説明する。図１において、シート状の強化繊維材料１を、熱可塑性樹脂粉末を分散媒に分散させたサスペンジョン浴２にガイドローラー３を介して導入する。強化繊維材料１がサスペンジョン浴２を通過する間に、樹脂粉末は強化繊維材料１に付着せしめられる。次いで、サスペンジョン浴２から取出された強化繊維材料１は、乾燥機４に導入され分散媒を除去することによって乾燥される。次いで、強化繊維材料１は加熱ゾーン５で樹脂を溶融する程度に加熱され、引き続き、上下一対の加熱・加圧ローラー６に導かれ、ローラー圧力３〜１０Ｋｇ／ｃｍ（計算線圧）、ローラー温度（Ｔｇ＋１５）〜（Ｔｇ＋１００）℃で加熱加圧される。かかる操作で強化繊維材料１に付着した樹脂粉末は溶融し、繊維材料表面及び繊維間に含浸せしめられる。次いで強化繊維材料は引取りローラー７を経て巻取りローラー８に巻き取られる。
An example of the production method of the present invention will be described with reference to FIG. In FIG. 1, a sheet-like reinforcing
本発明において用いられる熱可塑性樹脂を分散させるための分散媒は、アルコール類、ケトン類、ハロゲン化炭素類から選ばれた１種若しくは２種以上の有機溶媒又はかかる有機溶媒と水との混合溶媒である。アルコール類としては、メタノール、エタノール、イソプロピルアルコール、メチルセルソルブ等が、ケトン類としては、アセトン、メチルエチルケトン等が、ハロゲン化炭化水素類としては、塩化メチレン、ジクロロエタン等が挙げられる。中でも好ましいのは、エタノール、イソプロピルアルコール、アセトンあるいはそれらと水との混合溶媒である。かかる分散媒は、シート状の強化繊維材料を浸漬させたとき繊維材料を適度に開繊させるという作用もあるので、サスペンジョン中の樹脂粉末が繊維材料に均一に付着するのに効果的である。 The dispersion medium for dispersing the thermoplastic resin used in the present invention is one or more organic solvents selected from alcohols, ketones and halogenated carbons, or a mixed solvent of such an organic solvent and water. It is. Examples of alcohols include methanol, ethanol, isopropyl alcohol, and methyl cellosolve. Examples of ketones include acetone and methyl ethyl ketone. Examples of halogenated hydrocarbons include methylene chloride and dichloroethane. Of these, ethanol, isopropyl alcohol, acetone or a mixed solvent thereof with water is preferable. Such a dispersion medium also has an effect of appropriately opening the fiber material when the sheet-like reinforcing fiber material is immersed, so that it is effective for the resin powder in the suspension to uniformly adhere to the fiber material.
熱可塑性樹脂とそれを分散させるための分散媒（溶媒）との組合わせは、樹脂が溶媒に溶解するものであってはならず、樹脂が溶媒に膨潤するかあるいは溶解しないものである必要がある。 The combination of the thermoplastic resin and the dispersion medium (solvent) for dispersing the thermoplastic resin must not dissolve in the solvent, and the resin must swell or not dissolve in the solvent. is there.
サスペンジョン中の熱可塑性樹脂の濃度（（熱可塑性樹脂重量／分散媒重量＋熱可塑性樹脂重量）×１００）は、１〜５０重量％、好ましくは１〜３０重量％、さらに好ましくは５〜１５重量％である。 The concentration of the thermoplastic resin in the suspension ((thermoplastic resin weight / dispersion medium weight + thermoplastic resin weight) × 100) is 1 to 50% by weight, preferably 1 to 30% by weight, more preferably 5 to 15% by weight. %.
シート状の強化繊維材料を浸漬させるときのサスペンジョンの温度は、樹脂の分散状態が良好に保たれる限り特に制限はなく、また、用いられる熱可塑性樹脂や分散媒の種類、濃度によって異なるが、通常は５〜５０℃、好ましくは５〜３０℃、さらに好ましくは１５〜３０℃である。浸漬時間は、熱可塑性樹脂の付着量にも依存するが、通常は５〜１８０秒間で十分である。 The temperature of the suspension when immersing the sheet-like reinforcing fiber material is not particularly limited as long as the dispersion state of the resin is kept good, and varies depending on the type and concentration of the thermoplastic resin and dispersion medium used. Usually, it is 5-50 degreeC, Preferably it is 5-30 degreeC, More preferably, it is 15-30 degreeC. The immersion time depends on the amount of the thermoplastic resin attached, but usually 5 to 180 seconds is sufficient.
前記の様な条件の下で、シート状の強化繊維材料には１０〜７０重量％（繊維材料と熱可塑性樹脂の合計量に対して）の熱可塑性樹脂粉末が付着するが、プリプレグの製造上は２０〜５０重量％程度が適当である。 Under the above-mentioned conditions, 10 to 70% by weight (based on the total amount of the fiber material and the thermoplastic resin) of thermoplastic resin powder adheres to the sheet-like reinforcing fiber material. Is suitably about 20 to 50% by weight.
本発明においては、樹脂粉末の付着の均一性をより上げるために、シート状の強化繊維材料の浸漬時に、繊維材料とサスペンジョン浴との間で直流電流による通電処理を行っても良い。例えば、繊維材料が接触する浴外の電極ローラーを陽極とし、サスペンジョン浴中に陰極を設け、浴中にある繊維材料の単位表面積当たり、電流密度が０．００１〜５Ａ／ｍ２となるように通電すれば良い。 In the present invention, in order to further improve the uniformity of the adhesion of the resin powder, an energization process using a direct current may be performed between the fiber material and the suspension bath when the sheet-like reinforcing fiber material is immersed. For example, an electrode roller outside the bath in contact with the fiber material is used as the anode, a cathode is provided in the suspension bath, and the current density is 0.001 to 5 A / m 2 per unit surface area of the fiber material in the bath. Energize.
前記の様にして得られた熱可塑性樹脂粉末を付着せしめられたシート状の強化繊維材料は、通常、熱可塑性樹脂が分解又は反応しない温度下で乾燥される。一般的には、８０〜２００℃で１〜２０分間乾燥される。 The sheet-like reinforcing fiber material to which the thermoplastic resin powder obtained as described above is adhered is usually dried at a temperature at which the thermoplastic resin does not decompose or react. Generally, it is dried at 80 to 200 ° C. for 1 to 20 minutes.
次いで、乾燥された強化繊維材料は加熱ゾーン４で樹脂が溶融する程度に加熱される。加熱は、170〜390℃に加熱されたローラー間、又はスリット間を通すか、あるいはかかる温度の雰囲気中を通すことによって行うことができる。かかる処理によって付着した樹脂が溶融する。 Next, the dried reinforcing fiber material is heated in the heating zone 4 to such an extent that the resin melts. Heating can be performed by passing between rollers heated to 170 to 390 ° C. or between slits, or passing through an atmosphere of such a temperature. The resin adhered by such treatment is melted.
本発明においては、次いで強化繊維材料を、上下一対の加熱ローラーを用いてローラー圧力３〜１０Ｋｇ／ｃｍ（計算線圧）、好ましくは5〜10Ｋｇ／ｃｍで、ローラー温度（Ｔｇ＋１５）〜（Ｔｇ＋１００）℃、好ましくは（Ｔｇ＋２０）〜（Ｔｇ＋８０）℃で加熱して樹脂を含浸させ、シート状の強化繊維材料と熱可塑性樹脂を一体化させてプリプレグが製造される。かかる処理によってプリプレグの均一化と表面の平滑化が図られる。 In the present invention, the reinforcing fiber material is then subjected to a roller pressure of 3 to 10 kg / cm (calculated linear pressure) using a pair of upper and lower heating rollers, preferably 5 to 10 kg / cm, and a roller temperature (Tg + 15) to (Tg + 100). A prepreg is manufactured by heating at ℃, preferably (Tg + 20) to (Tg + 80) ℃, impregnating the resin, and integrating the sheet-like reinforcing fiber material and the thermoplastic resin. By this treatment, the prepreg is made uniform and the surface is smoothed.
本発明において、シート状の強化繊維材料と熱可塑性樹脂の接着力をより高めるためには、シート状の強化繊維材料に繊維の集束剤、油剤、糊剤等が付着している場合には、事前にこれらを除去しておく方が望ましい。また、必要な場合には、事前に繊維材料の開繊処理や、電解や薬品による表面処理を行っておいても良い。 In the present invention, in order to further increase the adhesive force between the sheet-like reinforcing fiber material and the thermoplastic resin, when a fiber sizing agent, oil agent, glue, etc. are attached to the sheet-like reinforcing fiber material, It is desirable to remove these in advance. If necessary, the fiber material may be opened in advance, or may be subjected to surface treatment with electrolysis or chemicals.
以下、具体的な実施例により本発明を説明する。各実施例及び比較例において、得られたプリプレグの均一性の評価は、（１）シート状の強化繊維材料への樹脂の含浸性の良否を示すボイド率、（２）プリプレグの厚みのバラツキから評価した。（１）のボイド率は硫酸分解法により測定した。（２）の厚みのバラツキは、シート状の強化繊維材料の幅方向に（200mm〜300mmの幅）20mm間隔で10点測定し、その平均値からの偏差値（％）で示した。また、プリプレグの表面の平滑性は、顕微鏡による断面観察で相対的に評価し、十分に平滑（◎）、かなり平滑（○）、平滑性に劣る（×）で示した。 Hereinafter, the present invention will be described with reference to specific examples. In each of the examples and comparative examples, the uniformity of the obtained prepreg was evaluated based on (1) a void ratio indicating the quality of resin impregnation into a sheet-like reinforcing fiber material, and (2) variation in prepreg thickness. evaluated. The void ratio of (1) was measured by a sulfuric acid decomposition method. The thickness variation of (2) was measured at 10 points at intervals of 20 mm in the width direction of the sheet-like reinforcing fiber material (width of 200 mm to 300 mm) and indicated by a deviation value (%) from the average value. Further, the smoothness of the surface of the prepreg was relatively evaluated by cross-sectional observation with a microscope, and indicated as sufficiently smooth (）), considerably smooth (◯), and inferior in smoothness (×).
ポリイミド樹脂（三井化学製ＰＩＸＡ−Ｍ）粉末（粒度分布、１０％：８μｍ、５０％：１２μｍ、９０％：１７μｍ）をアセトンに分散させ、７％濃度のサスペンジョンを調整した。サスペンジョン浴に炭素繊維Ａ（東邦テナックス社製IM600、単繊維直径5.0μｍ、12,000本）を平行に80本引き揃え、CF目付を145ｇ／ｍ２に調整したものを30〜60秒間浸漬し、樹脂の付着量が３５±３ｗｔ％になるように調整した。引き続いて、１５０℃で１〜5分間乾燥させ、表面温度が380〜390℃のローラーに通し樹脂を溶融する程度に加熱した。次いで、表面温度が２５０℃の上下一対のローラー間を５kgf/ｃｍの圧力で通し、樹脂を炭素繊維材料に十分に含浸させることにより、一体化した強化炭素繊維のプリプレグを得た。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 Polyimide resin (PIXA-M manufactured by Mitsui Chemicals) powder (particle size distribution, 10%: 8 μm, 50%: 12 μm, 90%: 17 μm) was dispersed in acetone to prepare a 7% concentration suspension. In a suspension bath, carbon fiber A (IM600 manufactured by Toho Tenax Co., Ltd., single fiber diameter: 5.0μm, 12,000 fibers) is aligned in parallel with 80 fibers adjusted to a CF basis weight of 145g / m 2 for 30 to 60 seconds. The adhesion amount of was adjusted to 35 ± 3 wt%. Subsequently, it was dried at 150 ° C. for 1 to 5 minutes and passed through a roller having a surface temperature of 380 to 390 ° C. to such an extent that the resin was melted. Next, an integrated reinforced carbon fiber prepreg was obtained by passing the resin between a pair of upper and lower rollers having a surface temperature of 250 ° C. at a pressure of 5 kgf / cm and sufficiently impregnating the carbon fiber material with the resin. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
炭素繊維Ａを60本平行に引き揃え、CF目付を133ｇ／ｍ２に調整したものを用い、樹脂の付着量が４０±３ｗｔ％になるように調整した以外は実施例１の場合と同じようにしてプリプレグを得た。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 The same as in Example 1 except that 60 carbon fibers A were aligned in parallel and the CF basis weight was adjusted to 133 g / m 2 and the amount of resin adhered was adjusted to 40 ± 3 wt%. A prepreg was obtained. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
実施例１においてローラー間の圧力を７kgf/ｃｍ、ローラー温度を２６０℃と変更して実験を繰り返しプリプレグを得た。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 In Example 1, the pressure between the rollers was changed to 7 kgf / cm and the roller temperature was changed to 260 ° C., and the experiment was repeated to obtain a prepreg. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
ローラー間の圧力を５kgf/ｃｍ、ローラー温度を２４０℃とする以外は実施例１と同じ条件でプリプレグを得た。実施例１のポリイミド樹脂のＴｇは２３５℃なので、この比較例では、ローラー温度が本発明の要件（Ｔｇ＋１５℃以上）を満足していない。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 A prepreg was obtained under the same conditions as in Example 1 except that the pressure between the rollers was 5 kgf / cm and the roller temperature was 240 ° C. Since Tg of the polyimide resin of Example 1 is 235 ° C., in this comparative example, the roller temperature does not satisfy the requirement of the present invention (Tg + 15 ° C. or more). Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
熱可塑性樹脂としてＰＰＳ（ポリフェニレンサルファイド、大日本インキ製）の粉末（平均粒子径：10μm）を用い、これをアセトンに分散させ、７％濃度のサスペンジョンを調整した。サスペンジョン浴に、実施例２の炭素繊維Ａと同じシート状の強化繊維材料を30〜60秒間浸漬し、樹脂の付着量が４０±３ｗｔ％になるように調整した。引き続いて、１５０℃で1〜5分間乾燥させ、表面温度が300〜320℃のローラーに通し樹脂を溶融する程度に加熱した。 次いで、表面温度が１３０℃の上下一対のローラー間を５kgf/ｃｍの圧力で通し、樹脂を炭素繊維材料に完全に含浸させることにより、一体化した強化炭素繊維のプリプレグを得た。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 PPS (polyphenylene sulfide, manufactured by Dainippon Ink) powder (average particle size: 10 μm) was used as the thermoplastic resin, and this was dispersed in acetone to prepare a 7% concentration suspension. In the suspension bath, the same sheet-like reinforcing fiber material as that of the carbon fiber A of Example 2 was immersed for 30 to 60 seconds, and the amount of resin adhered was adjusted to 40 ± 3 wt%. Subsequently, the film was dried at 150 ° C. for 1 to 5 minutes and passed through a roller having a surface temperature of 300 to 320 ° C. to the extent that the resin was melted. Next, an integrated reinforced carbon fiber prepreg was obtained by passing between a pair of upper and lower rollers with a surface temperature of 130 ° C. at a pressure of 5 kgf / cm and completely impregnating the carbon fiber material with the resin. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
ローラー間の圧力とローラー温度を表１に示した様に変更する以外は、実施例４と同じ様にプリプレグを製造した。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 A prepreg was produced in the same manner as in Example 4 except that the pressure between the rollers and the roller temperature were changed as shown in Table 1. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
ポリプロピレン樹脂（出光石化製）粉末（平均粒子径13μｍ）をアセトンに分散させ、７％濃度のサスペンジョンを調整した。サスペンジョン浴に炭素繊維Ｂ（東邦テナックス社製UT500、単繊維直径6.9μｍ、12,000本）を平行に30本引き揃え、CF目付を133ｇ／ｍ２に調整したものを30〜60秒間浸漬し、樹脂の付着量が３３±３ｗｔ％になるように調整した。引続いて、１５０℃で1〜5分間乾燥させ、表面温度が170℃のローラーに通し、樹脂を溶融する程度に加熱した。次いで、表面温度が８０℃の上下一対のローラー間を３kgf/ｃｍの圧力で通し、樹脂を炭素繊維材料に十分に含浸させることにより、一体化した強化炭素繊維のプリプレグを得た。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 Polypropylene resin (manufactured by Idemitsu Petrochemical) powder (average particle size 13 μm) was dispersed in acetone to prepare a 7% concentration suspension. In a suspension bath, carbon fiber B (UT500 manufactured by Toho Tenax Co., Ltd., single fiber diameter: 6.9μm, 12,000) was aligned in parallel, and the CF basis weight adjusted to 133g / m 2 was immersed for 30 to 60 seconds, and resin was added. The adhering amount was adjusted to 33 ± 3 wt%. Subsequently, it was dried at 150 ° C. for 1 to 5 minutes, passed through a roller having a surface temperature of 170 ° C., and heated to such an extent that the resin was melted. Next, an integrated reinforced carbon fiber prepreg was obtained by passing between a pair of upper and lower rollers having a surface temperature of 80 ° C. at a pressure of 3 kgf / cm and sufficiently impregnating the carbon fiber material with the resin. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
ローラー間の圧力とローラー温度を表１に示した様に変更する以外は、実施例５と同じ様にプリプレグを製造した。得られたプリプレグの厚みと厚みのバラツキ、ボイド率及び表面平滑性は表１に示した通りであった。 A prepreg was produced in the same manner as in Example 5 except that the pressure between the rollers and the roller temperature were changed as shown in Table 1. Table 1 shows the thickness and thickness variation, void ratio, and surface smoothness of the obtained prepreg.
表１の結果から、ローラー間の圧力及び温度が本発明の範囲内にある場合に限って、ボイド率と厚みのバラツキとも十分に満足すべきものが得られていることがわかる。 From the results shown in Table 1, it can be seen that only when the pressure and temperature between the rollers are within the range of the present invention, the satisfactory void ratio and thickness variation are obtained.
本発明の均一性と表面平滑性に優れたプリプレグは、目的に応じて、積層し、再度加熱、加圧して実質的に均一構造の複合材料に成形することが出来る。得られた複合材料は、優れた耐衝撃性等の機械的性質や優れた耐熱性等を有するので、航空・宇宙分野や一般産業分野に広く使用される。 The prepreg excellent in uniformity and surface smoothness according to the present invention can be laminated, heated and pressurized again according to the purpose, and formed into a composite material having a substantially uniform structure. Since the obtained composite material has excellent mechanical properties such as impact resistance and excellent heat resistance, it is widely used in aerospace and general industrial fields.
１ 強化繊維材料
２ サスペンジョン浴
３ ガイドローラー
４ 乾燥機
５ 加熱ゾーン
６ 一対の加熱・加圧ローラー
７ 引取りローラー
８ 巻取りローラー
Claims (8)
（１）４μｍ≦１０％での粒径
（２）８μｍ≦５０％での粒径≦１５μｍ
（３）９０％での粒径≦２０μｍ
（但し、粒径とは、レーザー回折散乱法により粒度分布を測定した場合において、累積グラフにおける各体積％での粒径を意味する。） The thermoplastic resin powder according to claim 5 or 6, wherein the thermoplastic resin powder has a particle size distribution measured by a laser diffraction scattering method and satisfies the following conditions (1), (2), and (3): The manufacturing method of the prepreg excellent in the uniformity and surface smoothness in any one.
(1) Particle size at 4 μm ≦ 10% (2) Particle size at 8 μm ≦ 50% ≦ 15 μm
(3) Particle size at 90% ≦ 20 μm
(However, the particle size means the particle size at each volume% in the cumulative graph when the particle size distribution is measured by the laser diffraction scattering method.)
The method for producing a prepreg excellent in uniformity and surface smoothness according to any one of claims 5 to 7, wherein the concentration of the thermoplastic resin in the suspension is 1 to 50% by weight.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004050519A JP2005239843A (en) | 2004-02-25 | 2004-02-25 | Prepreg excellent in homogeneity and surface smoothness, and its manufacturing method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004050519A JP2005239843A (en) | 2004-02-25 | 2004-02-25 | Prepreg excellent in homogeneity and surface smoothness, and its manufacturing method |
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| JP2005239843A true JP2005239843A (en) | 2005-09-08 |
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|---|---|---|---|
| JP2004050519A Pending JP2005239843A (en) | 2004-02-25 | 2004-02-25 | Prepreg excellent in homogeneity and surface smoothness, and its manufacturing method |
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| JP2008044165A (en) * | 2006-08-11 | 2008-02-28 | Toho Tenax Co Ltd | Method for producing prepreg excellent in uniformity |
| JP2008044999A (en) * | 2006-08-11 | 2008-02-28 | Toho Tenax Co Ltd | Process for producing prepreg excellent in uniformity |
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| CN105131520B (en) * | 2015-09-18 | 2017-05-31 | 中国兵器工业集团第五三研究所 | Glass fiber reinforcement PEEK one-way tapes and preparation method thereof |
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