JP2007015331A - Carbon fiber reinforcing resin drawing shaped article and its manufacturing material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carbon fiber reinforcing resin drawing shaped article and its manufacturing method capable of enhancing productivity and reducing manufacturing cost by simplifying the shaping method of an insulating layer and reducing the number of working steps during manufacturing relating to the manufacturing a drawing shaped article having high strength, being lightweight and which does not damage electronic parts. <P>SOLUTION: In a drawing shaping method in which bundled carbon fiber are impregnated with a thermosetting resin and drawn and shaped into a predetermined outer shape while heating and curing the thermosetting resin, an insulating sheet is arranged on the surface of the carbon fibers impregnated with the thermosetting resin, and thereafter they are integrally drawn and shaped into a predetermined outer shape while heating and curing the thermosetting resin. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a carbon fiber reinforced resin pultruded product, which is a resin reinforced with carbon fibers manufactured by a pultrusion method and suitable for housing and transporting electronic components, and a method for manufacturing the same.

Containers, racks, etc. used for storing and transporting electronic components must be strong enough to withstand the weight of electronic components and have basic performance such as excellent dust resistance. Until now, members formed of materials such as stainless steel and aluminum have been used.
However, in recent years, as electronic components have increased in size and mass production, the size of containers, racks, etc. has also increased, and when stainless steel is used, transportation becomes difficult due to the increase in weight due to the increase in size. In addition, when aluminum is used, there may be a problem in strength.

  Therefore, the present inventor has focused on carbon fiber reinforced resin (CFRP) whose strength is increased by carbon fiber as a material that has strength and can be reduced in weight, and has considered to replace it.

Since the fiber reinforced resin (FRP) is excellent in strength and heat resistance, and a molded product obtained by a pultrusion molding method has good productivity and moldability (see, for example, Patent Document 1), a container or the like is large. It is excellent in practicality when it is converted. In consideration of weight reduction, it is considered that a fiber using carbon fiber as the reinforcing fiber is particularly suitable.
Japanese Patent Laid-Open No. 5-117212

  Such a pultruded product has reached the stage of practical use because of its excellent strength and lightness, but because it uses carbon fiber to increase its strength, it is necessary to store electronic parts etc. There is a problem that the electronic component comes into contact with the surface of the container, the rack, etc., and energized to damage the expensive electronic component and become unusable.

Therefore, in order to solve such problems, the present inventor applied an insulating coating on the surface of a pultruded product of carbon fiber reinforced resin, provided an electrical insulating layer on the surface without impairing weight reduction, and sparked by electric current. The present inventors have found a pultruded product that can prevent energization due to the occurrence of the above.
This method requires a step of wiping the surface of the molded product with a solvent such as methanol after the pultrusion to prevent the paint film from peeling off. Therefore, there is still room for improving productivity and reducing costs by simplifying the method of forming the insulating layer and reducing the number of man-hours during manufacturing.

  Therefore, the present invention relates to the production of a carbon fiber reinforced resin pultruded molded product that is strong, lightweight, and does not damage electronic components, and simplifies the method of forming an insulating layer and reduces the number of manufacturing steps. Accordingly, an object of the present invention is to provide a carbon fiber reinforced resin pultruded molded product that can improve productivity and reduce manufacturing costs, and a manufacturing method thereof.

  A method for producing a carbon fiber reinforced resin pultruded product according to the present invention is a pultrusion method in which a bundled carbon fiber is impregnated with a thermosetting resin, and the thermosetting resin is heat-cured and pultruded into a predetermined outer shape. In this method, an insulating sheet is disposed on the surface of the carbon fiber impregnated with the thermosetting resin, and thereafter, the thermosetting resin is heat-cured and integrally formed into a predetermined outer shape. And

  According to the present invention, with respect to the manufacture of a pultruded product that is strong, lightweight, and does not damage electronic components, the productivity is reduced by simplifying the method of forming the insulating layer and reducing the number of manufacturing steps. It is possible to provide a carbon fiber reinforced resin pultruded molded product and a method for producing the same that can improve the manufacturing cost and reduce the manufacturing cost.

  Hereinafter, the present invention will be described in detail.

  The carbon fiber reinforced resin pultruded product of the present invention is composed of carbon fibers that are reinforcing fibers, a thermosetting resin that is reinforced with carbon fibers, and a sheet that is an insulating layer formed on the surface of the molded product. Yes.

The thermosetting resin used in the present invention is not particularly limited as long as it has heat resistance at the heating temperature at the time of pultrusion molding. For example, epoxy resin, polyimide resin, unsaturated polyester resin, phenol resin And urea resin.
These resins are usually used as a liquid resin composition together with necessary curing agents and curing accelerators.

  For example, the epoxy resin composition can be used by adding an epoxy resin and a curing agent as essential components and adding other components as appropriate. The details will be described below using an epoxy resin as an example.

  The epoxy resin, which is an essential component, should be widely used without being limited by the molecular structure, molecular weight, etc., as long as it has two or more epoxy groups in one molecule and can be used for pultrusion molding. Can do. Among these, an epoxy resin containing no halogen atom is preferable from the viewpoint of environmental conservation.

  Examples of this epoxy resin include epoxy resins having bisphenol type, novolak type and biphenyl type aromatic groups, epoxy resins in which polycarboxylic acids are glycidyl etherified, and alicyclic epoxy resins in which epoxy groups are condensed to cyclohexane derivatives. Among them, bisphenol A type epoxy resin, bisphenol F type epoxy resin, and alicyclic epoxy resin are particularly preferable. Moreover, these epoxy resins can be used individually or in mixture of 2 or more types.

  Examples of the bisphenol A type epoxy resin include Epicoat 828 (manufactured by Yuka Shell Epoxy), Araldite AER260 (manufactured by Ciba Geigy), and examples of the bisphenol F type epoxy resin include Epicoat 807 (manufactured by Yuka Shell).

  A trifunctional or higher functional epoxy resin has a particularly poor viscosity stability of a resin composition containing a curing agent, which may make it difficult to implement the present invention.

  The viscosity of an epoxy resin composition should just be a viscosity suitable for pultrusion molding, and it is preferable that it is the range of 0.3-0.5 Pa.s at 25 degreeC. Viscosity can be adjusted by adding a small amount of a reactive diluent such as phenyl glycidyl ether or butanediol diglycidyl ether (DY-026 manufactured by Ciba Geigy) as appropriate. Technology can be used.

  In addition, examples of the curing agent to be included in the epoxy resin composition include acid anhydrides and bases. However, the curing agent used at this time is a long pot life during the curing reaction of the resin composition. It is calculated | required that it is excellent in a moldability, and it is preferable that it is an acid anhydride. Furthermore, the resin composition satisfies the characteristics such as a small shrinkage ratio at the time of curing, high dimensional accuracy, high heat resistance, a cured product having excellent mechanical and electrical properties, and low irritation. It is also required.

  Examples of acid anhydrides used as the curing agent include chain aliphatic acid anhydrides, alicyclic acid anhydrides, aromatic acid anhydrides, and the like. For example, dodecyl succinic anhydride, maleic anhydride, methyl Examples thereof include nadic acid anhydride, phthalic anhydride, hexahydrophthalic anhydride, pyromellitic acid anhydride, trimellitic acid anhydride, and trimellitic acid glycol. Among these, an alicyclic acid anhydride is preferable because of its easy handling.

  Furthermore, if necessary, a curing accelerator may be mixed in the epoxy resin composition. Examples of the curing accelerator include amines such as benzyldimethylamine, triethylamine, dimethylaminomethylphenol, trisdimethylaminomethylphenol, and the like. Examples include imidazoles such as 2-ethyl-4-methylimidazole and 1-benzyl-2-methylimidazole, and these may be used alone or in admixture of two or more.

  This epoxy resin composition is blended with inorganic fillers such as aluminum hydroxide, gypsum and talc, flame retardants, UV degradation inhibitors, pigments, low shrinkage agents, etc., as long as they do not impair the properties of pultruded products. can do.

  The carbon fiber used in the present invention has an effect of increasing the strength of the cured product, particularly tensile strength, flexibility, impact resistance strength and the like. Although it can be used as roving, mat, cloth or an appropriate combination thereof, roving is preferred from the viewpoint of ease of molding and cost.

  Moreover, as this carbon fiber, what converged 6000-48000 carbon fiber filaments with a diameter of 5-15 micrometers can be used, for example, and 24,000-48000 carbon fiber filaments with a diameter of 6.7-7.0 micrometers converged. It is preferable that

  This carbon fiber contains 50 to 80% by mass of the pultruded product (excluding the mass of the sheet), and preferably 60 to 75% by mass. If it is less than 50% by mass, the strength becomes insufficient, and if it exceeds 80% by mass, the content of the epoxy resin decreases, and furthermore, the pulling resistance increases, so that molding becomes difficult.

  The sheet used in the present invention functions as an insulating layer, and prevents current from flowing from the conductive carbon fiber to the electronic component by preventing the carbon fiber contained in the pultruded product from contacting the electronic component. Is.

  Examples of the sheet include nonwoven fabrics such as natural fibers, synthetic fibers, and inorganic fibers, and woven fabrics. The material of the nonwoven fabric and the woven fabric is not particularly limited as long as it has insulating properties and heat resistance at the heating temperature at the time of pultrusion molding, but the nonwoven fabric of glass fiber, aramid fiber or polyester fiber or A woven fabric is preferred. This is because they have excellent performance as a constituent material of the electrical insulating layer and are highly reliable materials that have been used for many years.

  The thickness of the sheet (nonwoven fabric, woven fabric, etc.) that is an insulating layer may be 5 to 200 μm, and if it is less than 5 μm, sufficient insulation cannot be obtained, and if it exceeds 200 μm, the sheet is impregnated. It becomes worse and voids remain.

  This insulating layer may be formed so as to cover the entire carbon fiber reinforced resin pultruded product, or may be formed only on a part of the surface, but at least on the contact surface of the electronic component. is required. In view of cost, it is preferable to form an insulating layer only on the contact surface of the electronic component.

  Next, the manufacturing method of the carbon fiber reinforced resin pultruded product of this invention is demonstrated.

  In the present invention, an insulating sheet (nonwoven fabric, woven fabric, etc.) is disposed on the surface of the carbon fiber impregnated with the thermosetting resin, and the sheet is impregnated with the thermosetting resin and heated. A pultrusion molding method that is cured and continuously molded, for example, a pultrusion molding method, is performed to obtain a carbon fiber reinforced resin pultrusion molded product. Thereby, the insulating layer by a sheet | seat is formed in the surface of a molded article simultaneously with shaping | molding.

  FIG. 1 is a side sectional view of a pultrusion apparatus 1 showing an example of a method for producing a carbon fiber reinforced resin pultrusion product of the present invention. The carbon fiber roving 2 is continuously passed through an impregnation tank 3 containing a mixture of a thermosetting resin and a curing agent. In FIG. 1, the carbon fiber roving 2 is fed from two places, but the number of feeding is arbitrary. The sheet 6 is fed from the sheet roll 4 through the sheet insertion guide 5 to the surface of the carbon fiber roving 2 to which the thermosetting resin is adhered, and is fed to the heating mold 7. In FIG. 1, the sheet 6 is fed from two places, but the number of sheets fed is arbitrary.

  Due to the porosity of the sheet 6, the sheet 6 is impregnated with the thermosetting resin. Further, the thermosetting resin oozes out to the side opposite to the contact surface with the carbon fiber roving 2 impregnated with the thermosetting resin, and the surface of the sheet 6 is covered with the thermosetting resin. The carbon fiber roving 2 and the sheet 6 impregnated with the thermosetting resin are thermally cured in the heating mold 7. Since the sheet 6 is impregnated with the thermosetting resin, an insulating layer made of the sheet 6 is firmly formed on the surface of the molded product.

  The resin hardened product of the carbon fiber roving 2 and the sheet 6 thermally cured in the heating mold 7 is pulled by the pulling machine 8 to continuously form a molded product 9 having a constant cross section.

The molded article 9 continuously drawn is cut at a suitable length by a cutting device 10 perpendicularly to the axial direction to obtain a carbon fiber reinforced resin drawn molded article having an insulating layer formed on the surface of the molded article. Can do.
Since the surface of the heating mold 7 of the pultrusion molding apparatus is slippery and the surface of the molded body is covered with a thermosetting resin, the surface of the molded body is a smooth surface as a molding surface. Therefore, post-processing such as polishing for smoothing the surface of the molded body is unnecessary.

  The cross-sectional shape of the cut surface of the pultruded product obtained by the above steps may be any shape, for example, a circle, a triangle, a square, a U shape, or a U shape as shown in FIG. Examples of the shape include a shape and the like, which can be set to an arbitrary shape, and are determined by appropriately selecting the shape of the mold of the heating mold 7.

  The pultruded product is, for example, a plurality of pultruded products arranged in parallel, and one end or both ends of the pultruded product are connected and fixed to a support to form an electronic component housing portion, and the electronic component is placed thereon. It is possible to use a container, a rack, or the like. When an electronic component is accommodated, an insulating layer is formed on the contact part between the pultruded product and the electronic component, so that the electronic component is not affected by the carbon fiber of the pultruded product and is damaged. There is no worry about it.

  The insulating layer by the sheet may be formed so as to cover the entire carbon fiber reinforced resin pultruded product, or may be formed only on a part of the surface, but is formed at least on the contact surface of the electronic component. It is necessary.

  As described above, the production method of the present invention enables simplification of the formation method of the insulating layer (sheet) and reduction of man-hours during production, as compared with the case where insulation coating is performed on the surface of the molded product. Improvement in production performance and reduction in manufacturing cost can be achieved.

  EXAMPLES Next, although an Example demonstrates this invention, this invention is not limited to these Examples.

(Example)
100 parts by mass of bisphenol A type epoxy resin (Dainippon Ink Industries, trade name: Epicron 850S), 80 parts by mass of alicyclic acid anhydride (Dainippon Ink Industries, trade name: B-570), A liquid epoxy resin in which 2.5 parts by mass of imidazole-based curing accelerator (trade name: 2E4MZ, manufactured by Shikoku Kasei Co., Ltd.) and 2.0 parts by mass of carnauba wax was mixed was prepared in a container for impregnation.
Carbon fiber (manufactured by Toho Tenax Co., Ltd., trade name: Besfight HTA-24K) is impregnated in this liquid epoxy resin, and on one side of the carbon fiber impregnated with this epoxy resin, a polyester nonwoven fabric (manufactured by Asahi Kasei Co., Ltd., (Product name: Eltus, thickness 10 μm), supplied to a heating mold (length: 80 cm) at 170 ° C., heat-cured, pulled out at a speed of 30 cm / min to obtain a square pipe and cut with a cutting device .
As described above, an insulating layer (polyester nonwoven fabric) having a thickness of 10 μm is formed on one side, and a carbon fiber reinforced resin pultrusion molding having a square pipe shape (16 × 35 × 2 mm) containing 75% by mass of carbon fibers. Manufactured.
(Comparative example)
Prepare the same liquid epoxy resin as in the example, impregnate carbon fiber (manufactured by Toho Tenax Co., Ltd., trade name: Besfight HTA-24K) into this liquid epoxy resin, and in a 170 ° C mold (length 80 cm) Was pulled out at a speed of 30 cm / min to obtain a square pipe and cut with a cutting device.

  On one side of the obtained square pipe (16 × 35 × 2 mm), as an insulating resin for surface treatment, a two-component mixed room temperature dry epoxy resin (manufactured by Kyocera Chemical Co., Ltd., trade name: TEB9502 and Kyocera Chemical Co., Ltd.) (Product name: 1: 1 mixture with TEB9503) was applied and cured by a spray device to form an insulating layer having a thickness of 300 μm, and a carbon fiber reinforced resin pultruded product containing 75% by mass of carbon fiber was produced.

  The product weight, specific gravity, and insulation resistance of the carbon fiber reinforced resin pultruded molded products of Examples and Comparative Examples thus obtained were examined. The results are shown in Table 1.

[Specific gravity]: A test piece having a weight of 4 g was used and measured according to JIS K 6911.
[Insulation resistance]: Measured according to JIS K 6911.

As shown in Table 1, a molded product (Example) in which a polyester nonwoven fabric was formed on the surface and a molded product (Comparative Example) on which an insulating coating was formed showed similar values in all physical properties. When the insulation resistance of the surface of the molded article of the example was measured, it showed an electrical insulation property of 1 × 10 ¹¹ Ω or more as in the comparative example.

  Moreover, when a 50 kg load was applied to these pultruded products, it was found that they did not cause damage or deformation, and had sufficient strength for transportation of electronic components.

  On the other hand, a molded product having the same shape was obtained with stainless steel. However, when trying to make a product with the same weight as the pultruded molded product manufactured in the example, the plate thickness was too thin, about 0.4 mm, and 50 kg. It was confirmed that it could not withstand this load and deformed.

From the above results, the carbon fiber reinforced resin pultruded molded product of the present invention is lightweight and has sufficient strength and does not have an electrical effect on the contents. Suitable for storage.
In addition, the method for producing a carbon fiber reinforced resin pultruded molded product according to the present invention is such that an insulating layer is formed on the surface simultaneously with molding, and the molded product according to the present invention has the same electrical characteristics as a molded product coated with insulation. Shows characteristics such as insulation. Therefore, the carbon fiber reinforced resin pultruded product manufacturing method according to the present invention can simplify the method for forming the insulating layer and reduce the number of manufacturing steps, thereby improving productivity and reducing manufacturing cost. Can be planned.

It is a sectional side view of the manufacturing apparatus of the pultrusion molded product which concerns on embodiment of this invention. It is the figure which showed an example of the cross-sectional shape of the pultrusion molded product which concerns on embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Pull-out molding apparatus, 2 ... Carbon fiber roving, 3 ... Impregnation tank, 4 ... Sheet roll, 5 ... Sheet insertion guide, 6 ... Sheet, 7 ... Heating die, 8 ... Pulling machine, 9 ... Molded product, 10 ... Cutting device

Claims (5)

In a pultrusion method in which a focused carbon fiber is impregnated with a thermosetting resin, and the thermosetting resin is heat-cured and pultruded into a predetermined outer shape,
An insulating sheet is disposed on the surface of the carbon fiber impregnated with the thermosetting resin, and thereafter, the thermosetting resin is heat-cured and integrally formed into a predetermined outer shape. A method for producing a carbon fiber reinforced resin pultruded product.   The said sheet | seat consists of a nonwoven fabric or a woven fabric, The manufacturing method of the carbon fiber reinforced resin pultrusion molded product of Claim 1 characterized by the above-mentioned.   The said nonwoven fabric or woven fabric consists of at least 1 sort (s) chosen from glass fiber, an aramid fiber, and a polyester fiber, The manufacturing method of the carbon fiber reinforced resin pultrusion molded product of Claim 2 characterized by the above-mentioned.   The method for producing a carbon fiber-reinforced resin pultruded product according to any one of claims 1 to 3, wherein the molded product contains 50 to 80 mass% of the carbon fiber. In a carbon fiber reinforced resin pultruded product having a thermosetting resin and carbon fibers that are reinforcing fibers,
Containing 50 to 80% by mass of the carbon fiber,
The carbon fiber-reinforced resin pultruded product is characterized in that the insulating sheet impregnated with the thermosetting resin is integrally provided on the surface of the molded product by pultrusion molding.

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