JP2014527486A - 固化されている繊維束 - Google Patents
固化されている繊維束 Download PDFInfo
- Publication number
- JP2014527486A JP2014527486A JP2014525410A JP2014525410A JP2014527486A JP 2014527486 A JP2014527486 A JP 2014527486A JP 2014525410 A JP2014525410 A JP 2014525410A JP 2014525410 A JP2014525410 A JP 2014525410A JP 2014527486 A JP2014527486 A JP 2014527486A
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- JP
- Japan
- Prior art keywords
- fiber bundle
- winding
- solidified
- filaments
- impregnated material
- 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.)
- Granted
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Abstract
Description
a)粘性被覆を形成しながら、溶融物または溶液を平らなキャリアテープの上に付けるステップと、
b)平行のフィラメントを、このように被覆されているキャリアテープの上に、張力を掛けながら付けるステップと、
c)被含浸物を形成しながら、上記フィラメントを粘性被覆の中に押し込むステップと、
d)随意に、溶剤を蒸発させるステップ、熱的硬化させるステップ、および冷却させるステップの中の少なくとも1つのステップにより、上記被覆を、上記被含浸物の可塑的変形可能な状態まで部分的固化させるステップであって、このステップは、可塑的変形可能な状態が維持される程度にのみ行われ、特に、圧力装置を用いて、被覆の固化の間または後に、上記被含浸物に直接または間接に力が加えられる、ステップと、
e)被含浸物内のフィラメントの巻取張力を維持しながら、その被含浸物を巻き芯に巻きつけて巻きを形成するステップと、
f)随意には、巻きを、少なくとも1つのスリーブおよび/または少なくとも1つの粘着テープで、巻き芯の上に固定するステップと、
g)溶剤を蒸発させるステップ、熱的硬化させるステップ、および冷却させるステップの中の少なくとも1つのステップにより、上記被含浸物を固化させるステップと、
h)固化されている繊維束の形成のために、固化されている上記被含浸物を、特に、フィラメントが伸びる方向と平行および垂直に分割するステップと、を含み、
ここで、ステップg)の実施時に、巻きは加圧され、当該圧力は、被含浸物内のフィラメントの巻取張力により生成されている。
・単位面積質量および繊維の単位面積質量分、樹脂分、および全幅を亘っての少ない割れ目の発生に関して、変動が非常に低く、
・繊維束内の繊維の単位面積質量分は、50g/m2以上800g/m2以下の範囲、好ましくは100g/m2以上350g/m2以下の範囲、とりわけ200g/m2以上300g/m2にあり、
・合成樹脂の質量分が40%、被含浸物の単位面積質量が400g/m2である場合、樹脂分は、±3%、最大で±5%の正確さで設定可能であり、一方、張力を掛けながら硬化させるステップがない場合には、変動幅が±15%であり、
・切断された状態において向上した流動性:振動フィーダで配分する時に集結体および凝塊が生じず、さらに、張力を掛けながら硬化させるステップを行わずに製造された、長さおよび幅に亘って同様に分配したプレプレッグ部分に比べて、安息角がほぼ半分であり、
・切断時および切断された状態では、ダスト、特に、粒子状物質およびエアロゾルの質量分は、1%より低く、
・湿らされ、且つ、固化されているプレプレッグ部分または繊維束が、高い切断剪断強度(横断面に関する分裂力)を有し、当該切断剪断強度は、固化された、または、硬化された状態で70MPa以上150MPaであり(特許出願EP1 645 671 A1による従来技術による束の場合、約35MPa以上約55MPa以下のみが達成された)、
・高いタップ密度を発生させる、均一の浸透であり、フェノール樹脂で結合した炭素フィラメントの場合、タップ密度の値は、張力を掛ける硬化のステップがない場合に比べて、20%以上25%以下分だけ高い。
単一指向性プレプレッグが製造され、当該製造では、まず、液体のフェノールレゾール樹脂(135℃、60分間での不揮発性物質の質量分率が約71%、20℃でのヘプラー後の粘度がISO9371に従って測定すると750mPa s、Norsophen(登録商標) 1203, Hexion Specialy Chemicals)が、幅が1100mmであるシリコンで被覆された紙の上にキャリアテープとして塗布された。そのキャリアテープの単位面積質量は90g/m2、被覆された紙の厚さは0.07mmであった。樹脂塗布量は、±3%の測定された変動幅を伴って、プレプレッグ内の単位面積の樹脂量が190g/m2であった。樹脂の塗布の後に、1800mm隔てて、フィラメントの厚さが約7μmである、平面に広げた50k炭素フィラメント(Sigrafil(登録商標) C30 T050 EPZ, SGL CARBON SE、束毎に約50000個のフィラメント)が一斉に供給され、その際、供給されたカーボンフィラメントによって、単位面積質量が、285g/m2まで(±3%の同じ変動幅を伴って)高められた。キャリアテープの上における、得られた樹脂により浸透されたフィラメント層の幅は約1020mmであった。
それぞれ4つの上記ロールは、2×2のスロットのフレームの中に配置され、一緒に換気式炉内で乾燥されて硬化された。その際、以下の温度プログラムが維持された:
室温(23℃)から180℃まで、6℃/分の加熱速度で加熱すること、
150分間、180℃を維持すること、
60分以内に180℃から40℃まで冷却すること。
硬化された被含浸物が巻き戻され、その際、カバーテープ、キャリアテープ、および硬化されたプレプレッグは、分離されて巻き付けられた。次に、硬化されたプレプレッグのロールは、ロール切断機において、回転する刃部で、幅が40mmである部分ロールに切られた。ロール分離において用いられたいわゆる排除カットのため、この処理ステップにおいて失われた材料の質量分率は0.2%よりも少なかった。
11、12 偏向ローラ
20 キャリアテープ
21 塗布ローラ
22 固定したローラ
23 キャリアテープのための偏向ローラ
30 カバーテープ
31 カバーテープのための偏向ローラ
40 加熱テーブル
50、51、52、53、54、55 ローラのセット
60 冷却テーブル
70、71 牽引ローラ(メイン発動機)
72 単位面積質量の測定装置
80 巻き
Claims (16)
- 固化されている繊維束の製造方法であって、その製造方法は、
a)粘性被覆を形成しながら、溶融物または溶液を平らなキャリアウェブの上に付けるステップと、
b)平行のフィラメントを、このように被覆されているキャリアウェブの上に、張力を掛けながら付けるステップと、
c)被含浸物を形成しながら、上記フィラメントを粘性被覆の中に押し込むステップと、
d)随意に、溶剤を蒸発させるステップ、熱的硬化させるステップ、および冷却させるステップの中の少なくとも1つのステップにより、上記被覆を、上記被含浸物の可塑的変形可能な状態まで部分的固化させるステップであって、このステップは、可塑的変形可能な状態が維持される程度にのみ行われ、特に、圧力装置を用いて、被覆の固化の間または後に、上記被含浸物に直接または間接に力が加えられる、ステップと、
e)被含浸物内のフィラメントの巻取張力を維持しながら、その被含浸物を巻き芯に巻きつけて巻きを形成するステップと、
f)随意には、巻きを、少なくとも1つのスリーブおよび/または少なくとも1つの粘着テープで、巻き芯の上に固定するステップと、
g)溶剤を蒸発させるステップ、熱的硬化させるステップ、および冷却させるステップの中の少なくとも1つのステップにより、上記被含浸物を固化させるステップと、
h)固化されている繊維束の形成のために、固化されている上記被含浸物を、特に、フィラメントが伸びる方向と平行および垂直に分割するステップと、を含み、
ここで、ステップg)の実施時に、巻きは加圧され、当該圧力は、被含浸物内のフィラメントの巻取張力により生成されていることを特徴とする、固化されている繊維束の製造方法。 - 上記粘性融解物は、熱可塑性プラスチック、熱硬化性合成樹脂、ピッチ、および/または糖の融解物であることを特徴とする、請求項1に記載の製造方法。
- 上記溶液は、熱可塑性プラスチック、熱硬化性合成樹脂、特にフェノール樹脂、ピッチ、および/または糖の溶液であることを特徴とする、請求項1の記載の製造方法。
- 上記被含浸物は、上記ステップe)の前に、切断機で、フィラメントが伸びる方向と平行に細長い切れに切ることによって分けられることを特徴とする、請求項1から3までのいずれか1項に記載の製造方法。
- 固化されている被含浸物は、上記ステップh)の前に、切断機で、フィラメントが伸びる方向と平行に部分ロールに切ることによって分けられることを特徴とする、請求項1から4までのいずれか1項に記載の製造方法。
- 上記ステップd)の直後に、上記被含浸物はカバーウェブで被覆されることを特徴とする、請求項1から5までのいずれか1項に記載の製造方法。
- 上記フィラメントは炭素フィラメントを含むことを特徴とする、請求項1から6までのいずれか1項に記載の製造方法。
- 上記ステップa)では、溶液または有機物質の融解物が用いられ、上記ステップh)の次に、固化されている繊維束が、750℃以上1300℃以下の温度で、酸化剤なしで加工され、上記有機物質の少なくとも一部分が炭素に変換されていることを特徴とする、請求項1から7までのいずれか1項に記載の製造方法。
- 請求項1から8までのいずれか1項に記載の方法によって得られることを特徴とする、固化されている繊維束。
- 上記繊維束の幅は、当該繊維束内のフィラメントの長手伸びの方向の平均ベクトルに垂直な、繊維束の、大きいほうの各空間的長さの平均値として測定されて、0.1mm以上20mm以下、好ましくは0.5mm以上3mm以下であり、上記繊維束の長さは、当該繊維束内のフィラメントの長手伸びの方向の平均ベクトルと平行な、繊維束の、各空間的長さの平均値として測定されて、2mm以上50mm以下、好ましくは3mm以上20mm以下であることを特徴とする、請求項9に記載の固化されている繊維束。
- 上記繊維束の厚さは、当該繊維束内のフィラメントの長手伸びの方向の平均ベクトルに垂直な、繊維束の、小さいほうの各空間的長さの平均値として測定されて、0.05mm以上2mm以下、好ましくは0.1mm以上0.5mm以下であることを特徴とする、請求項9または10に記載の固化されている繊維束。
- 請求項1から8までのいずれか1項により製造された、固化されている繊維束を、熱可塑性プラスチックおよび/または熱硬化性合成樹脂のための補強手段としての使用。
- 上記固化されている繊維束で補強されている熱可塑性プラスチックまたは熱硬化性合成樹脂は、750℃以上1300℃以下の温度で、酸化剤なしで加工され、その熱可塑性プラスチックまたは熱硬化性合成樹脂の少なくとも一部分が炭化により炭素に変換されていることを特徴とする、請求項12に記載の使用。
- 請求項1から8までの製造方法に従って製造された固化されている繊維束が、750℃以上1300℃以下の温度で、酸化剤なしで、成形体として形成されて補強された熱可塑性プラスチックへ、および/または、成形体として形成された熱硬化性合成樹脂へと加工されることにより得られる成形体であって、ここで、上記熱可塑性プラスチックおよび/または熱硬化性合成樹脂の少なくとも一部分は、炭化により炭素に変換されており、炭化された成形体は、液体または気体の、カーバイドを形成する成分を用いた浸透で、特に、その成分の融点または沸点より高い温度にて、その成分からカーバイドを形成しながら加工されることを特徴とする、成形体。
- 請求項1から8までの製造方法に従って製造された、固化されている繊維束を補強手段とする使用であって、ここで、その固化されている繊維束は、炭素フィラメントから製造され、当該繊維束は、ピッチおよび微粉炭素の中から選択される少なくとも1つのさらなる成分を有する熱硬化性合成樹脂を含んだ混合物の中に補強手段として組み込まれていることを特徴とする、使用。
- 補強手段が備えられている混合物は、成形体を成すよう加工され、次に、その成形体は、750℃以上1300℃以下の温度で、酸化剤なしで加工され、ここで、熱硬化性合成樹脂およびピッチの少なくとも一部分は、炭化により炭素に変換されていることを特徴とする、請求項15に記載の使用。
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WO2016156222A1 (de) * | 2015-04-02 | 2016-10-06 | Evonik Degussa Gmbh | Verfahren und vorrichtung zur herstellung eines faserverbundwerkstoffs |
DE102015207815A1 (de) * | 2015-04-28 | 2016-11-03 | Technische Universität Dresden | Kohlefaser-Metall-Verbundwerkstoff |
JP6212146B2 (ja) * | 2016-02-23 | 2017-10-11 | 株式会社Subaru | 複合材賦形装置及び複合材賦形方法 |
US11505502B2 (en) * | 2016-10-24 | 2022-11-22 | Florida State University Research Foundation, Inc. | Hybrid multifunctional composite material and method of making the same |
DE102017101023A1 (de) | 2017-01-19 | 2018-07-19 | Airbus Operations Gmbh | Verfahren und eine Vorrichtung zur Herstellung eines Produktstrangs |
US11117362B2 (en) | 2017-03-29 | 2021-09-14 | Tighitco, Inc. | 3D printed continuous fiber reinforced part |
CN110678314B (zh) * | 2017-06-07 | 2022-08-02 | 陶氏环球技术有限责任公司 | 具有随机定向的长丝的模制化合物及其制作和使用方法 |
CN109532010B (zh) * | 2019-01-25 | 2023-06-16 | 南京航空航天大学 | 一种碳纤维复材变角度电损耗自加热原位固化装置及方法 |
EP3934832A4 (en) * | 2019-03-11 | 2022-12-14 | University of South Carolina | METHODS FOR PRODUCING LOW DEFECT RATE COMPOSITE FILAMENTS FOR ADDITIVE MANUFACTURING PROCESSES |
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CN112047749A (zh) * | 2020-07-29 | 2020-12-08 | 株洲红亚电热设备有限公司 | 一种碳碳坩埚及制造方法及感应加热炉 |
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