JP2014019083A - 炭素繊維ステッチ基材、およびそれを用いたウエット・プリプレグ - Google Patents
炭素繊維ステッチ基材、およびそれを用いたウエット・プリプレグ Download PDFInfo
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Abstract
【解決手段】 シート材1を、所定幅の炭素繊維糸条11・11…を互いに並行に配列して構成する一方、各シート材1の炭素繊維糸条11の配列方向を、前記ステッチ糸2の編み込み進行方向に対して±30〜±60°の角度をなすようにすると共に、
ステッチ糸2の編み込み進行方向に対するステッチ基材の1インチ幅当たり5Nの負荷による長手方向の伸長率を4%以下とし、かつ、25Nの負荷による長手方向の伸長率が10%以上となるようにした。
【選択図】 図1
Description
このシート材1を、所定幅の炭素繊維糸条11・11…を互いに並行に配列して構成する一方、各シート材1の炭素繊維糸条11の配列方向は、前記ステッチ糸2の編み込み進行方向に対して±30〜±60°の角度をなしているとともに、
ステッチ糸2の編み込み進行方向に対するステッチ基材の1インチ幅当たり5Nの負荷による長手方向の伸長率が4%以下であり、かつ25Nの負荷による長手方向の伸長率が10%以上にするという技術的手段を採用したことによって、炭素繊維ステッチ基材を完成させた。
編み込み率(R)=ステッチ糸の長さ(L2)/基材の長さ(L1)
L1:基材長さ
L2:ステッチに必要なステッチ糸の長さ
において、編み込み率(R)=3.5〜4.5の範囲で、ステッチするという技術的手段を採用することができる。
ステッチ糸2の編み込み進行方向に対するステッチ基材の1インチ幅当たり5Nの負荷による長手方向の伸長率が4%以下であり、かつ25Nの負荷による長手方向の伸長率が10%以上にして、
これら複数のシート材1・1…を積層して、ステッチ糸2を貫通させて編み込んで編絡一体化した炭素繊維ステッチ基材に、熱硬化性樹脂を30〜50重量%の範囲内で含浸して形成して、賦形性を有するようにするという技術的手段を採用することによって、ウエット・プリプレグを完成させた。
編み込み率(R)=ステッチ糸の長さ(L2)/基材の長さ(L1)
L1:基材長さ
L2:ステッチに必要なステッチ糸の長さ
破断荷重P(N)=糸の強度(N/tex)×糸繊度(tex)×配列密度(本/inch)
次に、本実施形態におけるウエット・プリプレグの成形について以下に説明する。炭素繊維ステッチ基材については、上記のとおりの手順で作製する。そして、この炭素繊維ステッチ基材に、熱硬化性樹脂を30〜50重量%の範囲内で含浸させて形成する。この熱硬化性樹脂としては、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂などが挙げられ、中でもエポキシ樹脂が好ましい。
次に、本実施形態のステッチ基材を具体的に作製したサンプルについての実験結果について説明する。
炭素繊維ステッチ基材としては、引張強度が5880MPa、引張弾性率が290GPa、繊度が1030tex(フィラメント数が24000本)の炭素繊維糸条を強化繊維として用い、炭素繊維糸条の目付が258g/m2となるよう互いに並行に配列したシートをステッチ糸の編み込み進行方向に対して±45°に積層した。
次に、ステッチ糸の組織を鎖編のみにした以外は、前記〔実施例1〕と同じ方法でステッチを行った。基材の伸長試験結果は図6の通りで、荷重5N時の伸長率は2.1%であり、25N時の伸長率は7.3%であった。
これは25N時の伸長率が7.3%であり、賦形させる際にシワを伸ばすため基材を引張っても変形し難いためといえる。
ステッチ糸の組織を1/1トリコット組織のみにした以外は〔実施例1〕と同じ条件でステッチ加工を行った。
編込み率を4.6とした以外は実施例1と同じ条件でステッチを行った。この〔比較例3〕では、荷重5N時の伸長率は5.1%であり、25N時の伸長率は22.3%であった。また、〔実施例1〕と同じ条件でウエット・プリプレグ加工を行った結果、乾燥炉内で基材の自重により基材が若干たて方向に伸ばされると同時に、幅方向にも若干収縮し、±45°方向に真っ直ぐに配向していた炭素繊維糸条が曲線状に乱れた。〔比較例2〕と比較するとその程度は小さかった。
11 炭素繊維糸条
2 ステッチ糸
3 補助糸
Claims (7)
- 複数のシート材(1・1…)を積層して、ステッチ糸(2)を貫通させて編み込んで編絡一体化したステッチ基材であって、
このシート材(1)は、所定幅の炭素繊維糸条(11・11…)が互いに並行に配列して構成されている一方、各シート材(1)の炭素繊維糸条(11)の配列方向は、前記ステッチ糸(2)の編み込み進行方向に対して±30〜±60°の角度をなしているとともに、
ステッチ糸(2)の編み込み進行方向に対するステッチ基材の1インチ幅当たり5Nの負荷による長手方向の伸長率が4%以下であり、かつ25Nの負荷による長手方向の伸長率が10%以上であることを特徴とする炭素繊維ステッチ基材。 - ステッチ糸(2)が、鎖編み組織と1/1トリコット組織との複合組織によりシート材(1)にステッチされていることを特徴とする請求項1記載の炭素繊維ステッチ基材。
- ステッチ糸(2)の編み込み進行方向と同じ方向に、補助糸(3)が挿入されていることを特徴とする請求項1または2記載の炭素繊維ステッチ基材。
- ステッチ糸(2)の編み込み進行方向に対してステッチ基材の1インチ幅当たり5〜25Nを負荷したときに、ステッチ糸(2)または補助糸(3)が切断可能であることを特徴とする請求項3記載の炭素繊維ステッチ基材。
- シート材(1)の炭素繊維糸条11の繊度が、400〜1200texであって、シート材(1)単独の目付が150〜400g/m2であることを特徴とする請求項1〜4の何れか一つに記載の炭素繊維ステッチ基材。
- ステッチ糸(2)が、以下に定義される編み込み率(R)
編み込み率(R)=ステッチ糸の長さ(L2)/基材の長さ(L1)
L1:基材長さ
L2:ステッチに必要なステッチ糸の長さ
において、編み込み率(R)=3.5〜4.5の範囲で、ステッチされていることを特徴とする請求項1〜5の何れか一つに記載の炭素繊維ステッチ基材。 - 複数のシート材(1・1…)を積層して、ステッチ糸(2)を貫通させて編み込んで編絡一体化したステッチ基材であって、
シート材(1)は、所定幅の炭素繊維糸条(11・11…)が互いに並行に配列して構成されている一方、各シート材(1)の炭素繊維糸条(11)の配列方向は、前記ステッチ糸(2)の編み込み進行方向に対して±30〜±60°の角度をなしているとともに、
ステッチ糸(2)の編み込み進行方向に対するステッチ基材の1インチ幅当たり5Nの負荷による長手方向の伸長率が4%以下であり、かつ25Nの負荷による長手方向の伸長率が10%以上であって、
これら複数のシート材(1・1…)を積層して、ステッチ糸(2)を貫通させて編み込んで編絡一体化した炭素繊維ステッチ基材に、熱硬化性樹脂が30〜50重量%の範囲内で含浸して形成され、賦形性を有することを特徴とするウエット・プリプレグ。
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