JP2018145222A - Fiber-reinforced composite material and method for producing fiber-reinforced composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber-reinforced composite material having high mechanical strength even when including a connection part, and a method for producing the same.SOLUTION: A fiber-reinforced composite material 1 has a first member 2 containing a first fiber 22 and a first resin 21, a second member 3 containing a second fiber 32 and a second resin 31, and a connection part 4 connecting the first member 2 and the second member 3, where a density of the connection part 4 is higher than a density of the first member 2 and a density of the second member 3. The first member 2 and the second member 3 preferably contain holes 23 and 33. The connection part 4 contains a first high density part 41 which contains the first fiber 22 and the first resin 21 and has a density higher than the first member 2, and a second high density part 42 which contains the second fiber 32 and the second resin 31 and has a density higher than the second member 3.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a reinforcing fiber composite material and a method for producing a reinforcing fiber composite material.

  For example, structural materials used for airplanes and automobiles are required to be further reduced in weight.

  As such a structural material, for example, a fiber reinforced resin obtained by mixing a reinforced fiber such as glass fiber and a resin is known. In such a fiber reinforced resin, the fibers are reinforced as a whole by being entangled with each other in all three-dimensional directions.

  In recent years, structural materials have been required to increase the mechanical strength and cope with an increase in size.

  Thus, it has been proposed to increase the strength of the structural material by using a papermaking body (composite molded body) (see, for example, Patent Document 1).

  On the other hand, in order to increase the size of the papermaking body, it is necessary to increase the size of the manufacturing apparatus, and the burden of equipment investment is a problem.

JP-A-4-174793

  Thus, it has been studied to efficiently increase the size of the structural material by connecting fiber reinforced resin members such as papermaking.

  However, when fiber reinforced resin members are connected to each other, there is a concern that the mechanical strength tends to decrease at the connection portion.

  An object of the present invention is to provide a reinforcing fiber composite material having a high mechanical strength even when a connection portion is included, and a method for manufacturing the same.

Such an object is achieved by the present inventions (1) to (9) below.
(1) a first member containing a first fiber and a first resin;
A second member containing a second fiber and a second resin;
A connecting portion to which the first member and the second member are connected;
Have
The reinforcing fiber composite material, wherein the density of the connection portion is higher than the density of the first member and the density of the second member.

(2) The reinforcing fiber composite material according to (1), wherein the first member includes pores.
(3) The reinforcing fiber composite material according to (2), wherein the second member includes pores.

(4) The connection portion includes a first high-density portion containing the first fiber and the first resin and having a higher density than the first member, the second fiber, and the second resin. The reinforcing fiber composite material according to (3), including a second high-density portion having a density higher than that of the second member.

  (5) The area of the interface between the first high-density portion and the second high-density portion is the area of the interface between the first member and the first high-density portion, and the second member and the second high-density portion. The reinforcing fiber composite material according to the above (4), which is larger than the area of the interface with the part.

  (6) The reinforcing fiber according to any one of (1) to (5), wherein one of the second member and the connection portion includes a concave portion and the other includes a convex portion that fits into the concave portion. Composite material.

  (7) The reinforcing fiber composite material according to any one of (1) to (6), wherein at least one of the first member and the second member is a papermaking body.

(8) preparing a first base material containing a first fiber and a first resin, and a second base material containing a second fiber and a second resin;
A connecting portion formed by compressing a part of the first base material and a part of the second base material, and connecting a part of the first base material and a part of the second base material; Obtaining a step;
The manufacturing method of the reinforced fiber composite material characterized by having.

  (9) In the step (8), the step of preparing the first base material and the second base material is a step of producing the first base material and the second base material by a papermaking method including a foaming process. The manufacturing method of the reinforced fiber composite material of description.

According to the present invention, it is possible to obtain a reinforced fiber composite material having high mechanical strength even if the connection portion is included.
Moreover, according to this invention, the said reinforced fiber composite material can be manufactured efficiently.

It is a perspective view which shows embodiment of the reinforced fiber composite material of this invention. It is the figure which added the partial enlarged view of each part to the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material shown in FIG. It is a figure for demonstrating the modification of the manufacturing method of the reinforced fiber composite material which concerns on embodiment shown in FIG. It is a figure for demonstrating another modification of the manufacturing method of the reinforced fiber composite material which concerns on embodiment shown in FIG. 5 is a perspective view showing a reinforcing fiber composite material of Comparative Example 1. FIG.

  Hereinafter, the reinforcing fiber composite material of the present invention and the method for producing the reinforcing fiber composite material will be described in detail based on preferred embodiments shown in the accompanying drawings.

<Reinforced fiber composite>
First, an embodiment of the reinforcing fiber composite material of the present invention will be described.

  FIG. 1 is a perspective view showing an embodiment of the reinforcing fiber composite material of the present invention, and FIG. 2 is a view in which a partial enlarged view of each part is added to the reinforcing fiber composite material shown in FIG.

  The reinforcing fiber composite material 1 shown in FIGS. 1 and 2 includes a first member 2, a second member 3, and a connection portion 4 that connects them. That is, the first member 2 and the second member 3 are connected by the connection portion 4 interposed therebetween.

  Further, the density of the connection portion 4 is higher than the density of the first member 2 and the density of the second member 3.

  In such a reinforced fiber composite material 1, the first member 2 and the second member 3 are firmly connected by increasing the density of the connection portions 4 as compared with the first member 2 and the second member 3. As a result, the reinforcing fiber composite material 1 having a larger size and higher mechanical strength can be easily realized.

Hereinafter, each part of the reinforcing fiber composite material 1 will be described in detail.
(First member)
First, the first member 2 will be described.

  The first member 2 includes a first resin 21 and first fibers 22. Such a first member 2 is compounded by dispersing the first fibers 22 in the matrix of the first resin 21, and exhibits high mechanical properties. Hereinafter, the first fiber 22 and the first resin 21 will be further described in detail.

-First fiber-
The first fibers 22 contribute to improving the mechanical properties of the first member 2. Moreover, since the 1st fiber 22 generally has higher heat conductivity than the 1st resin 21, it contributes also to improving the heat conductivity of the 1st member 2. FIG.

  As such 1st fiber 22, what was obtained by cut | disconnecting a fiber yarn or a long fiber bundle to predetermined length is used, for example.

  Although the average length of the 1st fiber 22 is not specifically limited, It is preferable that it is 1 mm or more, It is more preferable that it is 2 mm or more, It is further more preferable that it is 4 mm or more. By setting the average length of the first fibers 22 within the above range, the mechanical properties of the first member 2 can be sufficiently enhanced. In particular, even if the mechanical properties of the first resin 21 are relatively low, the first fibers 22 can sufficiently compensate for it. As a result, the first member 2 having particularly good mechanical characteristics can be obtained.

  Although the upper limit of the average length of the 1st fiber 22 is not specifically limited, For example, it is preferable that it is 100 mm or less, and it is more preferable that it is 50 mm or less. Thereby, when the 1st fiber 22 is disperse | distributed to a dispersion medium in manufacturing the 1st member 2, the dispersibility becomes favorable. As a result, a molded body having a uniform structure can be obtained, so that the first member 2 having excellent mechanical properties can be finally obtained.

  The average length of the first fibers 22 is the average of the lengths of any 100 or more first fibers 22 taken out by dissolving the first resin 21 of the first member 2 and the like. It means the value that was made.

  On the other hand, the average diameter of the first fibers 22 is not particularly limited, but is preferably about 1 to 100 μm, and more preferably about 5 to 80 μm. By setting the average diameter of the first fibers 22 within the above range, it is possible to improve the moldability when manufacturing the first member 2 while enhancing the mechanical characteristics of the first member 2.

  Note that the average diameter of the first fibers 22 is the average of measured diameters of any 100 or more first fibers 22 taken out by dissolving the first resin 21 of the first member 2 or the like. The value.

  Further, the ratio of the length to the diameter of the first fibers 22 (length / diameter) is preferably 10 or more, and more preferably 100 or more. Thereby, the 1st fiber 22 exhibits the above effects more certainly.

  Examples of such first fibers 22 include glass fibers, carbon fibers, aluminum fibers, copper fibers, stainless steel fibers, brass fibers, titanium fibers, steel fibers, and metal fibers such as phosphor bronze fibers, cotton fibers, and silk. Fiber, natural fiber such as wood fiber, ceramic fiber such as alumina fiber, wholly aromatic polyamide (aramid), wholly aromatic polyester, wholly aromatic polyester amide, wholly aromatic polyether, wholly aromatic polycarbonate, wholly aromatic Group polyazomethine, polyphenylene sulfide (PPS), poly (para-phenylenebenzobisthiazole) (PBZT), polybenzimidazole (PBI), polyetheretherketone (PEEK), polyamideimide (PAI), polyimide, polytetrafluoroethylene (PTFE), poly (para-phenyle) 2,6-benzobisoxazole) organic fibers and the like such as (PBO), those containing one or more of these (a plurality of kinds of fibers are mixed) is used.

  Among these, the mechanical properties of the first member 2 can be particularly enhanced by using inorganic fibers such as glass fibers, carbon fibers, metal fibers, and ceramic fibers as the first fibers 22.

  The first fiber 22 may be subjected to a surface treatment such as a coupling agent treatment, a surfactant treatment, an ultraviolet irradiation treatment, an electron beam irradiation treatment, or a plasma irradiation treatment as necessary.

  Among these, examples of the coupling agent include N- (β-aminoethyl) -γ-aminopropyltrimethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldimethoxysilane, and γ-aminopropylmethyl. Amino groups such as dimethoxysilane, γ-aminopropylmethyldiethoxysilane, γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldiethoxysilane Containing alkoxysilanes, hydrolysates thereof, and the like, and those containing at least one of these are used.

  On the other hand, further weight reduction of the 1st member 2 can be achieved by using the organic fiber mentioned above. In addition, organic fibers have various mechanical properties, and many have higher mechanical properties than inorganic fibers. Therefore, it is possible to realize the reinforcing fiber composite material 1 that achieves both high weight reduction and high mechanical properties by optimal selection of organic fibers.

  Moreover, the combined use of the inorganic fiber and the organic fiber makes it possible to achieve both the effect brought about by the inorganic fiber and the effect brought about by the organic fiber, thereby realizing a reinforced fiber composite material 1 with higher added value. be able to.

  Although content of the 1st fiber 22 in the 1st member 2 is not specifically limited, It is preferable that it is about 5-300 volume% of the 1st resin 21, and it is more preferable that it is about 10-150 volume%, 20 More preferably, it is about -90 volume%. By setting the content of the first fibers 22 within the above range, the quantitative balance between the first resin 21 and the first fibers 22 is optimized, so that the mechanical characteristics of the first member 2 are particularly enhanced. be able to. That is, when the content of the first fiber 22 is below the lower limit, the content of the first fiber 22 is relatively insufficient, so the composition of the first resin 21, the length of the first fiber 22, the constituent material, etc. Depending on the case, the reinforcing action by the first fibers 22 may be reduced, and the mechanical characteristics of the first member 2 may be deteriorated. On the other hand, if the content of the first fiber 22 exceeds the upper limit, the content of the first resin 21 is relatively insufficient, so the composition of the first resin 21, the length of the first fiber 22, the constituent material, etc. Depending on the case, the action of the first resin 21 for binding the first fibers 22 may be reduced, and the mechanical characteristics of the first member 2 may be deteriorated.

  In addition, the shape of the 1st fiber 22 shown in FIG. 3 is an example, and is not limited to linear shape as shown in figure, What kind of shape may be sufficient.

  Further, the first fibers 22 may be oriented in any direction in the first member 2, but are preferably oriented so as to be parallel to the surface. Thereby, toughness can be improved in the tensile direction of the surface of the first member 2. Moreover, the wear resistance and hardness of the surface of the first member 2 are also increased.

-First resin-
The first resin 21 imparts moldability and shape retention to the first member 2 or functions as a binder that binds the first fibers 22 together. Therefore, the first resin 21 is not particularly limited as long as it has such a function. For example, phenol resins, epoxy resins, unsaturated polyester resins, melamine resins, polyurethane, bismaleimide resins, thermosetting resins, polyamide resins (eg nylon), thermoplastic urethane resins, polyolefins Resin (eg, polyethylene, polypropylene, etc.), polycarbonate, polyester resin (eg, polyethylene terephthalate, polybutylene terephthalate, etc.), polyacetal, polyphenylene sulfide, polyether ether ketone, liquid crystal polymer, fluororesin (eg, polytetrafluoroethylene, polyfluoride) Vinylidene, etc.), modified polyphenylene ether, polysulfone, polyethersulfone, polyarylate, polyamideimide, polyetherimide, thermoplastic polyimide Thermoplastic resins such as. In addition, the 1st resin 21 may contain 1 type of these, and 2 or more types may be contained.

  The first resin 21 preferably contains at least one of a phenol resin, an epoxy resin, and a bismaleimide resin. Thereby, the mechanical characteristics and heat resistance of the first member 2 can be particularly enhanced.

  Among these, as the phenol resin, for example, phenol novolak resin, cresol novolak resin, bisphenol A novolak resin, novolak type phenol resin such as arylalkylene type novolak resin, unmodified resole phenol resin, tung oil, linseed oil, walnut oil Examples thereof include resol type phenol resins such as modified oil-modified resol phenol resins.

  Among these, a novolac type phenol resin is preferably used from the viewpoint of cost and moldability.

  Although the weight average molecular weight of a phenol resin is not specifically limited, It is preferable that it is about 1000-15000. In addition, when the weight average molecular weight of a phenol resin is less than the said lower limit, there exists a possibility that the viscosity of the 1st resin 21 may become low too much and the shaping | molding at the time of manufacture may become difficult. On the other hand, if the weight average molecular weight of the phenol resin exceeds the upper limit, the viscosity of the first resin 21 becomes too high, and the moldability at the time of manufacture may be lowered.

  The weight average molecular weight of the phenol resin can be determined as a weight average molecular weight in terms of polystyrene measured by gel permeation chromatography (GPC).

  Examples of the epoxy resin include bisphenol type epoxy resins such as bisphenol A type, bisphenol F type and bisphenol AD type, novolac type epoxy resins such as phenol novolak type and cresol novolak type, brominated bisphenol A type, brominated phenol. Examples thereof include brominated epoxy resins such as novolak type, biphenyl type epoxy resins, naphthalene type epoxy resins, and tris (hydroxyphenyl) methane type epoxy resins.

  Among these, bisphenol type epoxy resins and novolac type epoxy resins are preferably used from the viewpoints of high fluidity and moldability.

  Further, bisphenol A type epoxy resins, phenol novolac type epoxy resins, and cresol novolak type epoxy resins having a relatively low molecular weight are more preferably used.

  Furthermore, from the viewpoint of heat resistance, phenol novolac type epoxy resins and cresol novolac type epoxy resins are more preferably used, and tris (hydroxyphenyl) methane type epoxy resins are particularly preferably used.

  The bismaleimide-based resin is not particularly limited as long as it is a resin having maleimide groups at both ends of the molecular chain, for example, those having a benzene ring are preferable, and those represented by the following general formula (1) are more preferable. Preferably used.

［式中、Ｒ^１〜Ｒ^４は、置換基を有していてもよい炭素数１〜４の炭化水素基または水素原子を表す。また、Ｒ^５は、２価の有機基を表す。］

Wherein, R ¹ to R ⁴ represents a hydrocarbon group or a hydrogen atom of 1 to 4 carbon atoms which may have a substituent. R ⁵ represents a divalent organic group. ]

  However, the bismaleimide resin may have a maleimide group in addition to both ends of the molecular chain.

  Here, the organic group is a hydrocarbon group that may contain atoms other than carbon atoms, and examples of atoms other than carbon atoms include O, S, and N.

R ⁵ preferably has a main chain structure in which a methylene group, an aromatic ring, and an ether bond (—O—) are bonded in any order, and has at least one of a substituent and a side chain on the main chain. May be. The total number of methylene groups, aromatic rings and ether bonds contained in the main chain structure is 15 or less. Examples of the substituent or side chain include a hydrocarbon group having 3 or less carbon atoms, a maleimide group, and a phenylene group.

  Examples of bismaleimide-based resins include N, N ′-(4,4′-diphenylmethane) bismaleimide, bis (3-ethyl-5-methyl-4-maleimidophenyl) methane, and 2,2-bis [4- (4-maleimidophenoxy) phenyl] propane, m-phenylenebismaleimide, p-phenylenebismaleimide, 4-methyl-1,3-phenylenebismaleimide, N, N′-ethylenedimaleimide, N, N′-hexamethylene Examples thereof include dimaleimide.

A curing agent is used in combination with the first resin 21 as necessary.
For example, when a novolac type phenol resin is used as the first resin 21, hexamethylenetetramine is usually used as the curing agent.

  For example, when an epoxy resin is used as the first resin 21, the curing agent may be an amine compound such as an aliphatic polyamine, an aromatic polyamine, or diciamine diamide, an alicyclic acid anhydride, or an aromatic acid anhydride. An acid anhydride such as, a polyphenol compound such as a novolak type phenol resin, an imidazole compound, and the like are used.

  Among these, a novolak type phenol resin is preferably used from the viewpoints of handleability and environmental aspects. In particular, when using a phenol novolac type epoxy resin, a cresol novolac type epoxy resin, and a tris (hydroxyphenyl) methane type epoxy resin as an epoxy resin, as a curing agent, from the viewpoint that the heat resistance of the cured product is easily improved, A novolac type phenol resin is preferably used.

For example, when a bismaleimide resin is used as the first resin 21, an imidazole compound is used as the curing agent.
In addition, as a hardening | curing agent, the 1 type (s) or 2 or more types of what was mentioned above are used.

  On the other hand, the first resin 21 may particularly contain a thermoplastic resin. Thereby, the moldability of the 1st member 2 can be improved especially and the 1st member 2 with higher dimensional accuracy is obtained.

  Further, the first resin 21 preferably includes super engineering plastic among thermoplastic resins. Thereby, in addition to the effect which a thermoplastic resin brings, the effect of a high mechanical characteristic will be added. Examples of super engineering plastics include polysulfone, polyether sulfone, polyphenylene sulfide, polyether ether ketone, polyarylate, polyamide imide, polyether imide, polyether ether ketone, liquid crystal polymer, and fluororesin.

  Although melting | fusing point of the 1st resin 21 is not specifically limited, It is preferable that it is 200-400 degreeC, It is more preferable that it is 210-390 degreeC, It is further more preferable that it is 260-380 degreeC. By using the first resin 21 having such a melting point, the mechanical characteristics and heat resistance of the first member 2 can be sufficiently enhanced. Thereby, the reinforced fiber composite material 1 excellent in heat resistance is obtained.

  If the melting point of the first resin 21 is lower than the lower limit value, the dimensional accuracy of the reinforcing fiber composite material 1 at high temperatures may be lowered depending on the configuration of the first member 2 and the configuration of other parts. On the other hand, although the melting point of the first resin 21 may exceed the upper limit, some physical properties (for example, impact resistance) may be reduced accordingly.

  Here, the melting point of the first resin 21 is a crystal melting point in principle, and can be measured by, for example, a differential scanning calorimeter (DSC-2920, manufactured by TA Instruments).

  Further, when the first resin 21 has no crystal melting point and has a glass transition temperature, the melting point of the first resin 21 in the present invention includes the glass transition temperature. This glass transition temperature can also be measured by the differential scanning calorimeter.

  Further, when the first resin 21 is a thermosetting resin and neither the crystal melting point nor the glass transition temperature exists, the melting point of the first resin 21 in the present invention is the heat resistance temperature of the cured product of the thermosetting resin. Shall be included. This heat-resistant temperature is a deflection temperature under load defined in the general test method for thermoplastics of JIS K 6911: 1995.

-Pulp-
The 1st member 2 may contain the pulp as needed. Pulp is a fiber material having a fibril structure and is different from the first fiber 22. Pulp can be obtained, for example, by mechanically or chemically fibrillating the fiber material.

  In addition, when the reinforcing fiber composite material 1 is manufactured by a papermaking method, the cohesiveness of the material can be increased, so that the paper can be efficiently and stably made.

  Examples of the pulp include cellulose fibers such as linter pulp and wood pulp, natural fibers such as kenaf, jute and bamboo, para-type wholly aromatic polyamide fibers (aramid fibers) and copolymers thereof, aromatic polyester fibers, Examples include fibrillated organic fibers such as polybenzazole fibers, meta-type aramid fibers and copolymers thereof, acrylic fibers, acrylonitrile fibers, polyimide fibers, polyamide fibers, and at least one of these is Used.

  Further, the content of the pulp in the first member 2 is not particularly limited, but is preferably about 0.5 to 10% by mass of the first resin 21, more preferably about 1 to 8% by mass, More preferably, it is about 1.5-5 mass%. Thereby, the 1st member 2 with more favorable mechanical characteristics and thermal conductivity is realizable.

  Moreover, it is preferable that the average diameter of a pulp is smaller than the average diameter of the 1st fiber 22, Specifically, it is preferable that it is about 0.01-2 micrometers.

  Moreover, although the average length of a pulp is not specifically limited, It is preferable that it is about 0.1-100 mm, and it is more preferable that it is about 0.5-10 mm.

The BET specific surface area is used as an index for fibrillation of pulp. BET specific surface area of the pulp is not particularly limited, and is preferably about 3~25m ² / g, and more preferably about 5 to 20 m ² / g. Thereby, papermaking stability can be aimed at, when manufacturing the reinforced fiber composite material 1 with a papermaking method, fully ensuring the entanglement of pulp or the pulp and the 1st fiber 22. FIG.

-Flocculant-
The 1st member 2 may contain the flocculant as needed.

  Examples of the flocculant include a cationic polymer flocculant, an anionic polymer flocculant, a nonionic polymer flocculant, and an amphoteric polymer flocculant, and at least one of these is used.

  More specifically, for example, cationic polyacrylamide, anionic polyacrylamide, Hoffman polyacrylamide, mannic polyacrylamide, amphoteric copolymerized polyacrylamide, cationized starch, amphoteric starch, polyethylene oxide and the like can be mentioned.

  Further, the content of the flocculant in the first member 2 is not particularly limited, but is preferably about 0.01 to 1.5% by mass of the first resin 21 and about 0.05 to 1% by mass. Is more preferable, and it is still more preferable that it is about 0.1-0.5 mass%. Thereby, when manufacturing the 1st member 2 by a papermaking method, for example, a dehydration process etc. can be performed easily and stably, and the 1st member 2 which was finally uniform and excellent in the mechanical characteristic is obtained.

-Other additives-
The first member 2 may contain other additives as necessary.

  Examples of such additives include fillers, metal powders, antioxidants, ultraviolet absorbers, flame retardants, mold release agents, plasticizers, curing catalysts, curing aids, pigments, light resistance agents, antistatic agents, and antibacterial agents. , Conductive agents, dispersants and the like, and at least one of them is used.

  Among these, examples of the curing aid include imidazole compounds, tertiary amine compounds, organic phosphorus compounds, and magnesium oxide.

  In addition, as the filler, for example, an inorganic filler, an organic filler, or the like is used. Specific examples of constituent materials include oxides such as titanium oxide, alumina, silica, zirconia, magnesium oxide, and calcium oxide, nitrides such as boron nitride, aluminum nitride, and silicon nitride, barium sulfate, and sulfuric acid. Sulfides such as iron and copper sulfate, hydroxides such as aluminum hydroxide and magnesium hydroxide, minerals such as kaolinite, talc, natural mica and synthetic mica, carbides such as silicon carbide, etc. Is mentioned. Further, these powders may be subjected to a surface treatment such as a coupling agent treatment.

  Moreover, metal powder, glass beads, milled carbon, graphite, polyvinyl butyral, wood powder, etc. may be used as the filler.

  Moreover, as a mold release agent, a zinc stearate, a calcium stearate, a magnesium stearate etc. are mentioned, for example.

  Moreover, as a coupling agent, an epoxy silane coupling agent, a cationic silane coupling agent, an aminosilane coupling agent, a titanate coupling agent etc. are mentioned, for example.

  Examples of the flame retardant include metal hydroxides such as aluminum hydroxide and magnesium hydroxide, antimony compounds, halogen compounds, phosphorus compounds, nitrogen compounds, and boron compounds.

(Second member)
Next, the second member 3 will be described.

  Similar to the first member 2, the second member 3 includes a resin and a fiber and is a member to be connected to the first member 2, but the configuration is the same as that of the first member 2. It may be good or different. That is, the reinforced fiber composite material 1 was obtained by connecting the second member 3 having the same configuration to the first member 2 with the intention of simply increasing the size of the first member 2. Alternatively, it may be obtained by connecting the second member 3 having a different configuration to the first member 2 with the intention of having partially different physical properties.

  By connecting the first member 2 and the second member 3 via the connection portion 4, it is possible to easily increase the size of the reinforcing fiber composite material 1. For this reason, conventionally, the first member 2 itself was enlarged by using a large facility, for example, by enlarging the first member 2 itself, whereas in the present invention, the first member 2 was enlarged. By connecting the second member 3 and the second member 3, the reinforcing fiber composite material 1 can be increased in size without using a large facility.

  The second member 3 includes a second resin 31 and second fibers 32. Such a 2nd member 3 is compounded by disperse | distributing the 2nd fiber 32 to the matrix of the 2nd resin 31, and shows a high mechanical characteristic. Hereinafter, the second fiber 32 and the second resin 31 will be further described in detail.

-Second fiber-
The second fibers 32 contribute to enhancing the mechanical properties of the second member 3. Moreover, since the 2nd fiber 32 generally has higher heat conductivity than the 2nd resin 31, it contributes also to improving the heat conductivity of the 2nd member 3. FIG.

  As such 2nd fiber 32, the thing containing 1 type, or 2 or more types is used among what was mentioned as 1st fiber 22, for example.

  Further, the second fiber 32 may be the same as or different from the first fiber 22.

  When the second fiber 32 is different from the first fiber 22, the combination of the fibers is, for example, a combination in which one is an organic fiber and the other is an inorganic fiber, a combination in which both types are organic fibers, and both are different. Is a combination of different types of inorganic fibers, one is a relatively long fiber and the other is a relatively short fiber, one is a relatively thick fiber and the other is a relatively thin fiber, Examples include a combination in which one is an insulating fiber and the other is a conductive fiber.

  Among these, the reinforcement fiber composite material 1 formed by firmly connecting a member having insulation and a member having conductivity by adopting a combination in which one is an insulating fiber and the other is a conductive fiber. can get. Such a reinforced fiber composite material 1 becomes a high-value-added composite material utilizing each characteristic, and can also take advantage of the high mechanical strength.

  Moreover, the content rate of the 1st fiber 22 in the 1st member 2 and the content rate of the 2nd fiber 32 in the 2nd member 3 may mutually be the same, or may mutually differ.

-Second resin-
The second resin 31 is not particularly limited, and one containing one or more of the above-described ones as the first resin 21 is used.

  Further, the second resin 31 may be the same type of resin as the first resin 21 or may be a different type of resin.

  Further, the content ratio of the second resin 31 in the second member 3 and the content ratio of the second resin 31 in the second member 3 may be the same or different from each other.

-Pulp-
The 2nd member 3 may contain the pulp as needed.

  As a pulp added to the 2nd member 3, 1 type (s) or 2 or more types is used among what was mentioned as a pulp added to the 1st member 2, for example.

  In addition, the pulp added to the second member 3 may be the same as or different from the pulp added to the first member 2.

  Further, the pulp content in the first member 2 and the pulp content in the second member 3 may be the same or different from each other.

-Flocculant-
The second member 3 may contain a flocculant as necessary.

  As a flocculant added to the 2nd member 3, 1 type (s) or 2 or more types is used among what was mentioned as a flocculant added to the 1st member 2, for example.

  The flocculant added to the second member 3 may be the same as or different from the flocculant added to the first member 2.

  Further, the content of the flocculant in the first member 2 and the content of the flocculant in the second member 3 may be the same or different from each other.

-Other additives-
The second member 3 may contain other additives as necessary.

  As an additive added to the 2nd member 3, 1 type (s) or 2 or more types are used among what was mentioned as an additive added to the 1st member 2, for example.

  Further, the additive added to the second member 3 may be the same as or different from the additive added to the first member 2.

  Further, the additive content in the first member 2 and the additive content in the second member 3 may be the same or different from each other.

(Connection part)
Next, the connection part 4 is demonstrated.

  As described above, the connecting portion 4 is interposed between the first member 2 and the second member 3 and connects them.

  The density of the connection part 4 is higher than both the density of the first member 2 and the density of the second member 3. Thereby, since the mechanical strength of the connection part 4 is increased, even when structural continuity is lost at the interface between the first member 2 and the second member 3, the first member 2 and the second member 3. Can be firmly connected. As a result, the reinforcing fiber composite material 1 having high mechanical strength can be obtained while increasing the size and including the connection portion 4.

  The connection part 4 is preferably composed of a composite material including fibers and resin. Thereby, since it is easy to raise mechanical strength, the function as the connection part 4 improves more.

  Moreover, the connection part 4 has one or both of the site | part containing the 1st resin 21 and the 1st fiber 22 mentioned above, and the site | part containing the 2nd resin 31 and the 2nd fiber 32 mentioned above. It is preferable. Thereby, since the structural continuity with the 1st member 2 or the 2nd member 3, and the connection part 4 increases, the mechanical strength in the reinforced fiber composite material 1 can be raised more.

  The connecting portion 4 preferably includes a first high-density portion 41 that includes the first resin 21 and the first fibers 22 and has a higher density than the first member 2. Similarly, the connecting portion 4 preferably includes a second high-density portion 42 that includes the second resin 31 and the second fiber 32 and has a higher density than the second member 3. By having both the first high density portion 41 and the second high density portion 42 as described above, the connection portion 4 has structural continuity between both the first member 2 and the second member 3. It will be a thing. As a result, the structural continuity of the entire reinforcing fiber composite material 1 is ensured, and the mechanical strength can be particularly increased.

  Although the density of the 1st high density part 41 should just be higher than the density of the 1st member 2, it is preferable that a sufficient difference is ensured between both. Specifically, when comparing the porosity of the first high density portion 41 (the volume occupancy rate of the pores) and the porosity of the first member 2, the porosity of the first high density portion 41 is: The porosity may be lower than the porosity of the first member 2, and the difference is preferably 2% or more, more preferably 5% or more and 50% or less, and further preferably 10% or more and 50% or less. preferable. By setting the difference in porosity within the above range, it is possible to prevent the balance of mechanical strength from being lost while increasing the connection strength by the connection portion 4. That is, if the difference between the porosity of the first high-density portion 41 and the porosity of the first member 2 is less than the lower limit value, the density difference between the two becomes too small. May not be improved. On the other hand, if the difference in porosity exceeds the upper limit value, the mechanical strength of the first member 2 is likely to decrease, and the mechanical strength of the entire reinforcing fiber composite material 1 may be decreased.

  Similarly, the density of the second high-density portion 42 only needs to be higher than the density of the second member 3, but it is preferable that a sufficient difference is secured between the two members. Specifically, when the porosity of the second high-density portion 42 is compared with the porosity of the second member 3, the porosity of the second high-density portion 42 is the porosity of the second member 3. The difference is preferably 2% or more, more preferably 5% or more and 50% or less, and still more preferably 10% or more and 50% or less. By setting the difference in porosity within the above range, it is possible to prevent the balance of mechanical strength from being lost while increasing the connection strength by the connection portion 4. That is, if the difference between the porosity of the second high density portion 42 and the porosity of the second member 3 is less than the lower limit value, the density difference between the two becomes too small, so that the connection strength by the connection portion 4 is sufficient. May not be improved. On the other hand, if the difference in porosity exceeds the upper limit value, the mechanical strength of the second member 3 tends to be lowered, and the mechanical strength of the entire reinforcing fiber composite material 1 may be lowered.

  In addition, in the interface 43 (refer FIG. 1, 2) of the 1st high density part 41 and the 2nd high density part 42, the element which comprises each part may mutually be mixed. For example, the first resin 21 and the first fiber 22 may enter the second high density portion 42 side, while the second resin 31 and the second fiber 32 enter the first high density portion 41 side. You may go out.

  Further, the interface 43 between the first high-density portion 41 and the second high-density portion 42 may be a surface that extends in any direction. In the example shown in FIGS. 1 and 2, the interface 43 between the first high-density portion 41 and the second high-density portion 42 has a flat surface in which the plate-shaped first member 2 extends and a plate-shaped second member 3 expands. It includes a surface that is substantially parallel to the plane. In other words, the connecting portion 4 shown in FIGS. 1 and 2 has a plate shape, and the first high-density portion 41 and the second high-density portion 42 have a surface that divides the thickness into two as an interface 43. And is touching. Such an interface 43 is easy to ensure a relatively wide area when connecting the first member 2 and the second member 3. For this reason, the connection part 4 including such an interface 43 contributes to further increasing the mechanical strength of the reinforcing fiber composite material 1.

  On the other hand, at the interface 44 (see FIGS. 1 and 2) between the first high-density portion 41 and the second member 3, elements constituting each portion may be mixed with each other. For example, the first resin 21 and the first fiber 22 may enter the second member 3 side, while the second resin 31 and the second fiber 32 enter the first high density portion 41 side. Also good.

  The same applies to the interface 45 (see FIGS. 1 and 2) between the second high-density portion 42 and the first member 2. For example, the second resin 31 and the second fiber 32 may enter the first member 2 side, while the first resin 21 and the first fiber 22 enter the second high density portion 42 side. Also good.

  Here, the interface between the first member 2 and the first high-density portion 41 is defined as an interface 46 (see FIGS. 1 and 2). Although the density differs at the interface 46, the contained fibers, resins, and the like are the same across the interface 46.

  Further, the interface between the second member 3 and the second high-density portion 42 is defined as an interface 47 (see FIGS. 1 and 2). Although the density differs at the interface 47, the fibers, resins, etc. contained are the same across the interface 47.

  The area of the interface 43 between the first high-density portion 41 and the second high-density portion 42 described above may be smaller than the area of the interface 46 and the area of the interface 47, but preferably the area of these interfaces 46. And it is set to be larger than the area of the interface 47. Thereby, mechanical strength can be further increased in the entire reinforcing fiber composite material 1. That is, at the interface 46 and the interface 47, since the fibers and the resin are the same across the interface, the connection strength is relatively high even if the area is small. On the other hand, at the interface 43, since fibers and resins may be different across the interface 43, it is necessary to supplement the connection strength by increasing the area. Therefore, by making the area of the interface 43 larger than the area of the interface 46 or the area of the interface 47, the balance of the mechanical strength at each interface is achieved, and the mechanical strength of the entire reinforcing fiber composite material 1 is increased. Can be increased.

  The area of the interface 43 is preferably 1.1 times or more than the area of the interface 46, more preferably 1.5 times or more, and even more preferably 2 times or more. Similarly, the area of the interface 43 is preferably 1.1 times or more of the area of the interface 47, more preferably 1.5 times or more, and even more preferably 2 times or more. Thereby, the balance of mechanical strength at each interface can be further optimized. As a result, the weak point can be particularly reduced in terms of mechanical strength, and the mechanical strength of the entire reinforcing fiber composite material 1 can be particularly increased. At this time, the upper limit value is not particularly set. However, considering that the interface 43 becomes too large, the connection portion 4 is increased in size, and consequently, the weight of the reinforcing fiber composite material 1 is increased. Is preferable, and it is more preferably about 5000 times or less.

  The first member 2 may be a dense body, but preferably includes holes 23 (see FIG. 2). Thereby, since the weight reduction of the 1st member 2 is achieved, the reinforced fiber composite material 1 which is lightweight and has high mechanical strength is obtained. When the 1st member 2 contains the void | hole 23, it is preferable that the porosity (volume occupation rate of a void | hole) is about 5% or more and 90% or less, and it is more preferable that it is about 10% or more and 80% or less. Preferably, it is about 15% or more and 70% or less. Thereby, it is possible to achieve a sufficient weight reduction while maintaining the mechanical strength of the first member 2. As a result, a reinforced fiber composite material 1 that is lightweight and has high mechanical strength is obtained.

  The second member 3 may be a dense body, but preferably includes a hole 33 (see FIG. 2). Thereby, since the weight reduction of the 2nd member 3 is achieved, the reinforced fiber composite material 1 which is lightweight and has high mechanical strength is obtained. When the second member 3 includes the holes 33, the porosity (volume occupation ratio of the holes) is preferably about 5% or more and 90% or less, more preferably about 10% or more and 80% or less. Preferably, it is about 15% or more and 70% or less. Thereby, sufficient weight reduction can be achieved, maintaining the mechanical strength of the 2nd member 3. FIG. As a result, a reinforced fiber composite material 1 that is lightweight and has high mechanical strength is obtained.

  These porosity ratios can be replaced by the area ratios of the holes 23 and the holes 33 obtained in the cross section of the first member 2 and the second member 3.

  Further, each of these holes 23 and 33 may be a space (closed cell) in which one or more of the holes are connected to each other, and communicates with the outside of the system. It may be a space (open cell).

  Among these, although there is no particular limitation, it is preferable that there are more closed cells than open cells. Thereby, even if it contains a void | hole, the mechanical strength of the 1st member 2, the 2nd member 3, and the connection part 4 becomes difficult to fall more. This is because the closed cells are difficult to collapse, and the mechanical strength due to bending or the like is not easily lowered accordingly.

  The term “the number of closed cells is larger than that of open cells” refers to a state in which the total area occupied by closed cells is larger than the total area occupied by open cells when the cross section is enlarged and observed.

  Moreover, the average diameter of these holes 23 and 33 is not particularly limited, but is preferably about 2 to 500 μm, and more preferably about 5 to 300 μm. Thereby, the weight reduction by including the holes 23 and 33 and the reduction of the mechanical strength accompanying the holes 23 and 33 can be made compatible. That is, when the average diameter of the holes 23 and 33 is less than the lower limit value, it is difficult to increase the porosity, and thus the weight reduction of the reinforcing fiber composite material 1 may be insufficient. On the other hand, when the average diameter of the holes 23 and 33 exceeds the upper limit value, the holes 23 and 33 are likely to become a starting point of refraction, cracking, and the like, so that mechanical strength may be lowered.

  The average diameter of the holes 23 and 33 is obtained as the diameter of the circle (equivalent circle diameter) when a circle having the same area as the holes 23 and 33 is assumed from the cross section.

  Moreover, although the 1st member 2 and the 2nd member 3 may each be manufactured by what kind of method, it is preferable that at least one of these is a papermaking body. A papermaking body is a structure in which fibers are dispersed, which is obtained by papermaking a dispersion containing fibers. According to such a papermaking body, relatively long fibers are intertwined with each other, so that the mechanical strength is easily increased. Therefore, even when the fiber content is suppressed or the porosity is increased, the reinforced fiber composite material 1 having high mechanical strength can be obtained.

  It is to be noted that structures containing fibers are known other than paper products (for example, injection-molded articles, extruded articles, etc. of compositions containing fiber fillers). Particularly, a structure in which long fibers are uniformly dispersed is used. A papermaking body is also preferably used from the viewpoint that it is easy to obtain.

  Moreover, it is preferable that the connection part 4 is also a papermaking body like the above. Thereby, since the mechanical strength of the connection portion 4 is also increased, the connection strength between the first member 2 and the second member 3 can be particularly increased.

  As mentioned above, although the reinforced fiber composite material 1 was demonstrated, this reinforced fiber composite material 1 is applicable to all structures. As an example, an interior material for transportation equipment can be exemplified. Specifically, cabin ceiling panel, cabin interior panel, cabin floor, cockpit ceiling panel, cockpit interior panel, cockpit floor, baggage locker wall, storage locker wall, door lining, window cover, captain's seat, co-pilot Seats, passenger cabin seats, various seats such as passenger seats, various interior materials for aircraft such as restroom interior materials, automotive interior materials, marine interior materials, railroad interior materials, spacecraft interior materials, etc. Is mentioned. All such interior materials for transport equipment are required to be lightweight and have high mechanical strength from the viewpoint of safety and transport efficiency. For this reason, the reinforced fiber composite material 1 is particularly preferably used.

  In addition, the reinforced fiber composite material 1 may be applied to the entirety of these interior materials for transport equipment, or may be applied to only a part thereof.

Here, it is preferable that the reinforcing fiber composite material 1 has the following characteristics.
First, the bending strength of the reinforcing fiber composite 1 is not particularly limited, but is preferably about 30 to 400 MPa, more preferably about 50 to 350 MPa, and further preferably about 60 to 300 MPa. Thereby, even if the connection part 4 is included, the reinforced fiber composite material 1 having sufficiently high mechanical properties can be obtained. That is, the reinforced fiber composite material 1 that achieves both large size and mechanical strength is obtained.

  In addition, the bending strength of the reinforcing fiber composite material 1 is measured at room temperature (25 ° C.) according to a test method defined in ISO 178: 2001. The bending direction at this time is a direction in which a stress that pulls the interface 44 or 45 is generated. For example, in the case of FIG. 1, both the first member 2 and the second member 3 may be pushed downward while the connection portion 4 is held.

The specific strength of the reinforcing fiber composite 1 is not particularly limited, but is preferably about 50 to 400 MPa · (g / cm ³ ) ⁻¹ , and is about 100 to 390 MPa · (g / cm ³ ) ⁻¹ . More preferably, it is about 150 to 380 MPa · (g / cm ³ ) ⁻¹ . Thereby, the reinforced fiber composite material 1 in which both reduction in weight and improvement in mechanical properties are achieved can be obtained. If the specific strength falls below the lower limit, it can be said that the bending strength is small for a heavy weight, so that, for example, it is inappropriate as a reinforced fiber composite material 1 in the industrial field where both weight reduction and high mechanical properties are required. There is a risk. On the other hand, if the specific strength exceeds the above upper limit value, it can be said that the bending strength is large for light weight, but depending on the balance with other physical properties, the impact resistance is reduced, and variations due to manufacturing conditions are likely to occur. It may be difficult to increase the manufacturing yield.

The specific strength of the reinforcing fiber composite 1 is determined by dividing the bending strength (unit: MPa) by the density (unit: g / cm ³ ).

Further, specific modulus of the reinforcing fiber composite material 1 is not particularly limited, but is preferably 2~30GPa · ^{(g /} cm ³⁾ about ^{-1, 3~25GPa · (g / cm} 3) about ^-1 It is more preferable that it is about 4 to 20 GPa · (g / cm ³ ) ⁻¹ . Thereby, the reinforced fiber composite material 1 in which both reduction in weight and improvement in mechanical properties are achieved can be obtained.

In addition, the specific elastic modulus of the reinforced fiber composite material 1 is obtained by dividing the bending elastic modulus (unit: GPa) by the density (unit: g / cm ³ ). And a bending elastic modulus is measured according to the test method prescribed | regulated to ISO178: 2001 at room temperature (25 degreeC).

<Method for producing reinforcing fiber composite>
Next, an example of the manufacturing method of the reinforcing fiber composite material 1 shown in FIG. 1 (embodiment of the manufacturing method of the reinforcing fiber composite material of the present invention) will be described.

  3-10 is a figure for demonstrating the method (embodiment of the manufacturing method of the reinforced fiber composite material of this invention) which manufactures the reinforced fiber composite material 1 shown in FIG. 1, respectively.

  The method for producing the reinforcing fiber composite material 1 according to the present embodiment includes the steps of preparing (preparing) the first base material 20 and the second base material 30 by a papermaking method including a foaming process, and the first base material 20. The connecting portion 4 is formed by overlapping and compressing the part 201 of the second base material 30 and the part 301 of the second base material 30 so that the part 201 of the first base material 20 and the part 301 of the second base material 30 are connected. Obtaining. Hereinafter, each process will be described sequentially.

[1] Step of preparing (preparing) a first base material and a second base material [1-1] First dispersion including first resin 21, first fiber 22, and dispersion medium 51 for dispersing them. A liquid 61 is prepared (see FIG. 3). The prepared first dispersion 61 is sufficiently stirred and mixed. The first dispersion 61 may contain the above-described flocculant, pulp, other additives, and the like as necessary.

  The shape of the 1st resin 21 in this process is not specifically limited, For example, it is set as particulate form (powder form), such as substantially spherical particle form and thin film particle form, or fibrous form. Thereby, in the papermaking mentioned later, the 1st resin 21 can be made with the 1st fiber 22. As a result, the first resin 21 and the first fibers 22 can be entangled uniformly, and the homogeneous first base material 20 can be obtained. The first base material 20 becomes the first member 2 and the first high-density portion 41 through subsequent pressure molding.

  In addition, when the 1st resin 21 contains a thermosetting resin, it is preferable that the thermosetting resin is a semi-hardened state. The semi-cured thermosetting resin is molded into a desired shape by heating and pressurization after the first base material 20 is manufactured, and then cured. Thereby, the reinforced fiber composite material 1 utilizing the characteristics of the thermosetting resin is obtained.

  On the other hand, as the first fiber 22, for example, a fiber having a melting point higher than that of the first resin 21 may be used. By using such first fibers 22, only the first resin 21 can be selectively melted when the first base material 20 is pressure-formed while being heated in a process described later. As a result, the first resin 21 can be melted and dispersed around the first fibers 22, and a homogeneous reinforcing fiber composite 1 can be obtained.

  The melting point of the first fiber 22 only needs to be higher than the melting point of the first resin 21, but the difference is preferably 10 ° C. or higher, more preferably 50 ° C. or higher.

  In addition, as the dispersion medium 51, a material that is difficult to dissolve the first resin 21 and the first fibers 22 and that hardly volatilizes in the process of dispersing the first resin 21 and the first fibers 22 is preferably used. Moreover, what is easy to remove a solvent is used preferably. From this viewpoint, the boiling point of the dispersion medium 51 is preferably about 50 to 200 ° C.

  Examples of the dispersion medium 51 include alcohols such as water, ethanol, 1-propanol, 1-butanol and ethylene glycol, ketones such as acetone, methyl ethyl ketone, 2-heptanone and cyclohexanone, ethyl acetate, butyl acetate and acetoacetate. Examples include esters such as methyl acetate, ethers such as tetrahydrofuran, isopropyl ether, dioxane, and furfural, and at least one of these is used.

  Among these, water is preferably used. Water is useful as the dispersion medium 51 because it is readily available, has a low environmental impact, and is highly safe.

  The content of the dispersion medium 51 in the first dispersion 61 is not particularly limited, but is preferably about 10 to 1000 times the solid content.

  In addition, when the pores 23 are formed in the first member 2, the microcapsules 52 having thermal expansibility are added to the first dispersion 61. The microcapsule 52 expands and becomes a hole 23 when heated. That is, you may make it finally produce the 1st preform | base_material 20 and the 2nd preform | base_material 30 with the papermaking method including the process to foam.

  The microcapsules 52 having thermal expansion are particles obtained by microencapsulating a volatile liquid foaming agent with a thermoplastic shell polymer having gas barrier properties. Such a microcapsule 52 functions as a foaming agent by the following mechanism. When the microcapsule 52 is heated, the outer shell of the capsule is softened, and the liquid foaming agent contained in the capsule is vaporized to increase the pressure. As a result, the capsule expands and hollow spherical particles are formed. The hollow spherical particles remain even after pressure molding, and consequently contribute to the formation of pores.

  Examples of the liquid blowing agent include low boiling point hydrocarbons such as isopentane, isobutane, and isopropane.

  Examples of the thermoplastic shell polymer include polyacrylonitrile, vinylidene chloride-acrylonitrile copolymer, vinylidene chloride-methyl methacrylate copolymer, vinylidene chloride-ethyl methacrylate, acrylonitrile-methyl methacrylate copolymer, acrylonitrile-ethyl methacrylate, and the like. These may be used alone or in combination of two or more.

  Examples of the microcapsule 52 include commercially available products such as EXPANSEL (manufactured by Nippon Ferrite Co., Ltd.), Microsphere F50, Microsphere F60 (above, manufactured by Matsumoto Yushi Seiyaku Co., Ltd.), Advancel EM (manufactured by Sekisui Chemical Co., Ltd.). Can be used.

  The addition amount of the microcapsule 52 is preferably about 0.05 to 10% by mass of the first resin 21, and more preferably about 0.1 to 5% by mass.

  [1-2] Next, the prepared first dispersion 61 is made. Thereby, the 1st papermaking body shape 20a is obtained (refer FIG.5 (b)).

  Specifically, first, as shown in FIG. 4, a container 70 having a filter 71 on the bottom surface is prepared.

  Next, the first dispersion 61 is supplied into the container 70. Then, the dispersion medium 51 in the first dispersion 61 is discharged from the bottom surface of the container 70 to the outside through the filter 71. As a result, the first resin 21, the first fibers 22, and the microcapsules 52, which are dispersoids in the first dispersion 61, together with some dispersion medium 51, are placed on the filter 71 as shown in FIG. Remains (papermaking). By drying this residue, a first papermaking shape 20a shown in FIG. 5 (b) is obtained.

  Note that the first papermaking body 20a may include a thermoplastic resin having a melting point lower than that of the first resin 21 (hereinafter, referred to as “low melting point resin”) as necessary. By including this low melting point resin, it is possible to further improve the shape retention of the first papermaking shaped body 20a and the intermediate obtained in the subsequent steps. That is, when the first papermaking body 20a is heated at a temperature lower than the heating temperature in pressure molding (for example, drying), the low melting point resin melts and the first fibers 22, the first resins 21 or the first The resin 21 and the first fiber 22 are bound. Thereby, it becomes easy to maintain the shape of the first papermaking body 20a and other intermediates. As a result, the dimensional accuracy and mechanical properties of the finally obtained reinforcing fiber composite material 1 are not easily lowered. In addition, the first papermaking feature 20a is less likely to lose its shape, making it easier to grip the first papermaking feature 20a and increasing the portability. Thereby, the operation | work which arrange | positions the 1st papermaking body shape 20a, for example in a shaping | molding die can be performed easily.

  The shape of the low melting point resin before melting is not particularly limited, and may be in the form of particles (powder) such as substantially spherical particles or thin film particles, or may be in the form of fibers.

  Further, the content of the low melting point resin in the first papermaking shape 20a is not particularly limited, but is preferably about 0.5 to 30% by volume, more preferably about 1 to 20% by volume. More preferably, it is about 10 to 10% by volume. Thereby, the effect of improving the shape-retaining property of the first papermaking shaped body 20a and other intermediates by adding the low-melting-point resin is ensured sufficiently and without impairing the above-described effects.

  The melting point of the low melting point resin is preferably about 10 to 250 ° C. lower than the melting point of the first resin 21, more preferably about 50 to 200 ° C. Due to such a difference in melting point, the low melting point resin is melted in a process such as drying, and is easily decomposed and removed when heated at a high temperature. For this reason, the function which a low melting-point resin has can be exhibited to the maximum. That is, the low melting point resin works to maintain its shape before the first papermaking body 20a is heated at a high temperature, and the mechanical characteristics are lowered after the first papermaking body 20a is heated at a high temperature. Can be suppressed.

  In addition, the 1st papermaking body shape 20a obtained by doing in this way may contain the dispersion medium 51, or does not need to contain it.

  [1-3] Next, the first papermaking body 20a is placed in the cavity 721 of the mold 72 (see FIG. 6). At this time, the volume of the cavity 721 is set to be larger than the volume of the first papermaking body 20a (short shot).

  Subsequently, the first papermaking body 20a is heated. Thereby, the microcapsule 52 expands, and the volume of the first papermaking body 20a increases accordingly. As a result, the cavity 721 is filled and molded by the expansion pressure of the first papermaking body 20a (see FIG. 7).

  The conditions for heating the first papermaking shape 20a are not particularly limited, but it is preferable to heat at a heating temperature of 140 to 270 ° C. for about 5 minutes to 2 hours.

Further, the expansion pressure of the first papermaking shaped body 20a when the microcapsule 52 expands is not particularly limited, but is preferably about 1 to 5 MPa.
As described above, the first base material 20 formed into the target shape is obtained (see FIG. 8).

  In addition, when the 1st papermaking body shape 20a is heated, a part of 1st resin 21 may fuse | melt. Thereby, since the shape retention property of the 1st base material 20 can be improved more with the molten 1st resin 21, it becomes easy to hold | grip the 1st base material 20, and portability becomes high, and handling in a subsequent process Good. Further, when the first resin 21 is a thermoplastic resin, the entire first resin 21 may be melted.

  [1-4] Next, a second dispersion liquid containing the second resin 31, the second fibers 32, and the dispersion medium 51 for dispersing them is prepared. In addition, since this 2nd dispersion liquid is prepared similarly to the 1st dispersion liquid 61, the description is abbreviate | omitted.

  Next, the prepared second dispersion is subjected to papermaking to obtain a second papermaking shape. Since this second papermaking feature is also prepared in the same manner as the first papermaking feature 20a, its description is omitted.

  Next, the 2nd preform | base_material 30 is obtained using the prepared 2nd papermaking body shape (refer FIG. 8). Since this 2nd base material 30 is prepared similarly to the 1st base material 20, the description is abbreviate | omitted.

[2] Step of Obtaining Connection Part [2-1] First, a part 201 of the first base material 20 and a part 301 of the second base material 30 are overlapped to obtain a laminated body (see FIGS. 8 and 9). ). In FIG. 9, for convenience of explanation, the surface of a part 201 of the first base material 20 is hatched.

  At this time, the overlapping amount of the part 201 of the first base material 20 and the part 301 of the second base material 30 is the interface 43 between the first high density part 41 and the second high density part 42 in the connection part 4 described above. Will affect the area. For this reason, this overlap amount is appropriately set in consideration of the size and specific gravity of the finally obtained reinforcing fiber composite material 1, the required mechanical strength, and the like.

  Further, the part 201 of the first base material 20 and the part 301 of the second base material 30 may have a constant thickness or may be partially different.

  [2-2] Next, the obtained laminate is heated while compressing the first base material 20 and the second base material 30 so as to approach each other (see FIG. 8). Thereby, the connection part 4 by which the part 201 of the 1st base material 20 and the part 301 of the 2nd base material 30 are connected is obtained. As a result, the reinforcing fiber composite material 1 shown in FIG. 10 is obtained.

  When compressing the laminate, as shown in FIG. 8, the laminate is sandwiched between a flat plate-shaped mold 74 and a mold 75, and the mold 74 and the mold 75 are compressed while being brought close to each other. At this time, heating is performed simultaneously.

  Thereby, the part 201 of the 1st base material 20 and the part 301 of the 2nd base material 30 are compressed preferentially, since the thickness in a laminated body is relatively thick. By this compression, the holes 23 included in the part 201 of the first base material 20 and the holes 33 included in the part 301 of the second base material 30 are reduced or eliminated by being crushed. As a result, the part 201 of the first base material 20 and the part 301 of the second base material 30 are each compressed until the thickness becomes about half.

  On the other hand, the other part 202 other than the part 201 of the first base material 20 and the other part 302 other than the part 301 of the second base material 30 are compressed with a delay because the thickness of the laminated body is relatively thin. The However, in the example of FIG. 8, since the thickness of the 1st preform | base_material 20 and the thickness of the 2nd preform | base_material 30 are substantially the same level, it is hardly compressed. As a result, the other part 202 of the first base material 20 and the other part 302 of the second base material 30 are substantially maintained at their original thicknesses even after compression is completed.

  Thus, the 1st preform | base_material 20 containing the hole 23 and the 2nd preform | base_material 30 containing the hole 33 show plasticity by being largely crushed in the case of compression, and this plastic exhibits favorable connection strength. It becomes a cause.

  In addition, you may make it arrange | position the spacer 76 which regulates the thickness of the reinforced fiber composite material 1 after compression between the shaping | molding die 74 and the shaping | molding die 75 as needed. By interposing such a spacer 76, the distance between the forming die 74 and the forming die 75 can be regulated, so that the compression width of the first base material 20 and the second base material 30 can be controlled. As a result, the first base material 20 and the second base material 30 are prevented from being excessively compressed, and the reinforcing fiber composite material 1 having a target thickness can be obtained.

  Moreover, since a laminated body is compressed and heated, the 1st resin 21 contained in the 1st preform | base_material 20 fuse | melts, and flows between 1st fibers 22 mutually. Thereafter, the first fibers 21 are cured or solidified, whereby the first fibers 22 are bound to each other by the first resin 21. Thereby, a part 201 of the first base material 20 is cured or solidified in a compressed state, and becomes the first high-density portion 41 shown in FIG. Further, the other portion 202 of the first base material 20 is hardened or solidified with the holes 23 included, and becomes the first member 2 shown in FIG.

  Further, the second resin 31 contained in the second base material 30 melts and flows between the second fibers 32. Thereafter, the second resin 31 is cured or solidified, whereby the second fibers 32 are bound to each other by the second resin 31. Thereby, the part 301 of the 2nd preform | base_material 30 hardens | cures or solidifies in the compressed state, and becomes the 2nd high density part 42 shown in FIG. Further, the other portion 302 of the second base material 30 is hardened or solidified while containing the holes 33, and becomes the second member 3 shown in FIG.

  As described above, the connection portion 4 including the first high density portion 41 and the second high density portion 42 is obtained. And the reinforced fiber composite material 1 by which the 1st member 2 and the 2nd member 3 are connected via the connection part 4 is obtained.

  The heating temperature at this time is appropriately set according to the composition of the first resin 21 and the second resin 31, but is preferably about 150 to 350 ° C. as an example, and is about 160 to 300 ° C. More preferred.

  Moreover, although the heating time at this time is suitably set according to heating temperature, it is preferable that it is about 1 to 180 minutes, and it is more preferable that it is about 5 to 60 minutes.

  Moreover, although the applied pressure at this time is suitably set according to heating temperature and heating time, it is preferable that it is about 0.05-80 MPa, and it is more preferable that it is about 0.1-60 MPa.

(Modification)
Next, the modification of the manufacturing method of the reinforced fiber composite material which concerns on this embodiment is demonstrated.

  FIG. 11 is a diagram for explaining a modification of the method for manufacturing the reinforcing fiber composite material according to the embodiment shown in FIG. 9.

  FIG. 11 is the same as FIG. 9 except for the shape in plan view of the part 201 when the part 201 of the first base material 20 and the part 301 of the second base material 30 overlap each other. It is. In FIG. 11, for convenience of explanation, the surface of a part 201 of the first base material 20 is hatched.

  Specifically, a part 201 of the first base material 20 shown in FIG. 11 includes a portion forming an anchor shape in plan view. The anchor shape in this specification refers to a shape protruding toward the second base material 30 side. By including such an anchor shape, the reinforcing fiber composite material 1 includes a structure in which the connecting portion 4 and the second member 3 mesh with each other.

  The meshed structure is a structure in which the connection portions 4 and the second members 3 are alternately arranged in a direction orthogonal to the direction in which the part 201 of the first base material 20 protrudes. According to such a structure, it is possible to secure a wider contact area between the connection portion 4 and the second member 3. As a result, since the frictional resistance of the contact surface becomes larger, the reinforcing fiber composite material 1 in which the connection strength between the first member 2 and the second member 3 is further reinforced can be obtained.

  The anchor shape is not particularly limited. For example, as shown in FIG. 11, the anchor shape protrudes toward the second base material 30 side, and the width of the protruding proximal end portion is narrower than the width of the protruding distal end portion. It may be a shape. With such a shape, the protruding tip is locked to the second base material 30. Thereby, sufficient proof stress arises with respect to the load to the direction which pulls the 1st member 2 and the 2nd member 3 especially. As a result, the connection strength between the first member 2 and the second member 3 can be further increased.

  In the reinforcing fiber composite 1 manufactured as shown in FIG. 11, the connection portion 4 is formed by a part 201 of the first base material 20 and a part 301 of the second base material 30. Since the connecting portion 4 has a protruding shape (a shape including a convex portion), the connecting portion 4 is fitted to a shape including the concave portion of the second member 3. Such a structure in which a convex portion is fitted in the concave portion can particularly widen the contact area between the two. For this reason, the reinforced fiber composite material 1 with especially high connection strength is obtained.

  FIG. 12 is a diagram for explaining another modification of the method for manufacturing the reinforcing fiber composite material according to the embodiment shown in FIG. 9.

  In FIG. 12, the first base material 20, the second base material 30, the third base material 40, and the fourth base material 50 are connected. A part of the first base material 20 overlaps a part of the second base material 30 and a part of the third base material 40. Further, a part of the second base material 30 overlaps a part of the fourth base material 50. Further, a part of the third base material 40 overlaps a part of the fourth base material 50.

  In addition, as shown in FIG. 12, a part of the first base material 20 and a part of the fourth base material 50 each include a portion having an anchor shape.

  On the other hand, although hidden behind in FIG. 12, a part of the second base material 30 and a part of the third base material 40 each include a portion having an anchor shape.

  The reinforced fiber composite material 1 can also be manufactured by connecting three or more base materials (four base materials in FIG. 12).

  Note that when the base materials are connected in such an arrangement, the shape of the connecting portion becomes a strip shape extending between the base materials. Moreover, this connection part will spread in a grid | lattice form. The lattice shape means a state in which two sets of parallel strip-shaped connecting portions having different extending directions intersect each other. By having the connection part spreading in such a lattice shape, the reinforcing fiber composite material 1 has higher mechanical strength.

  As mentioned above, although the reinforced fiber composite material of this invention and the manufacturing method of the reinforced fiber composite material were demonstrated based on embodiment of illustration, this invention is not limited to these.

  For example, the reinforcing fiber composite material of the present invention may be obtained by adding an arbitrary element to the embodiment.

  Moreover, the manufacturing method of the reinforced fiber composite material of this invention may add the arbitrary process to the said embodiment, and may replace the order of each process of the said embodiment.

Next, specific examples of the present invention will be described.
1. Production of reinforcing fiber composite (Example 1)
[1] First, resol type phenolic resin (manufactured by Sumitomo Bakelite Co., Ltd., product number PR-51723), aramid fiber (manufactured by Teijin Ltd., product number T32PNW, average length 6 mm, average diameter 12 μm), and aramid pulp (DuPont) Manufactured, product number para-aramid pulp) and thermally expandable microcapsules were added to water and stirred for 20 minutes with a disperser. Here, a dispersion having a solid content concentration of 0.6% by mass was obtained. The blending ratio is as shown in Table 1.

  Next, a flocculant (polyethylene oxide, molecular weight 1000000) dissolved in water in advance in the obtained first dispersion is 0.2% with respect to the above-described solid content (components other than water in the first dispersion). It added in the ratio of the mass%, and solid content was aggregated.

  Next, water was removed from the agglomerates obtained using a 30 mesh metal net. Then, the agglomerate remaining on the metal net was subjected to dehydration press and further dried at 70 ° C. for 3 hours to obtain a first papermaking shape.

  Next, the obtained first papermaking body was placed in a mold and heated at 180 ° C. for 10 minutes. As a result, the thermally expandable microcapsule was expanded to obtain a base material containing pores. The internal pressure in the mold at this time was 2 MPa.

  [2] Next, two base materials prepared as described above were prepared, and one was used as a first base material and the other was used as a second base material, and these were connected as follows. In addition, each base material was made into the plate shape of length 60mm x width 60mm x thickness 15mm.

  First, both were arrange | positioned so that a part of 1st base material and a part of 2nd base material might overlap. The overlapping width was 20 mm.

  Next, these were sandwiched between flat plate molds and compressed while being heated. The heating conditions at this time were a temperature of 200 ° C., a time of 10 minutes, and a pressure of 10 MPa.

  By this pressurization, a part of the first base material and a part of the second base material were integrated to form a connection portion, and a reinforced fiber composite material was obtained.

(Comparative Example 1)
13 is a perspective view showing a reinforcing fiber composite material of Comparative Example 1. FIG.

  Rather than arranging the first base material and the second base material so as to overlap each other, heating is performed while the end surfaces of the base materials are arranged so as to abut each other (so that the overlap width is zero). A reinforced fiber composite material 1 ′ was obtained in the same manner as in Example 1 except that it was manufactured by compression.

(Examples 2-11 and Comparative Examples 2-5)
A reinforced fiber composite material was obtained in the same manner as in Example 1 except that the production conditions of the composite molded body were changed as shown in Table 1 or Table 2.

2. 2.1 Evaluation of Reinforcing Fiber Composite Material 2.1 Evaluation of Appearance, etc. With respect to the reinforcing fiber composite material of each example and each comparative example, the appearance, density, porosity and the like were evaluated.

  First, with respect to the thickness of the reinforcing fiber composite material, the thicknesses of the first base material and the second base material were substantially maintained. Moreover, about the 1st member and the 2nd member, the porosity of each base material was substantially maintained.

  On the other hand, regarding the porosity of the connecting portion, a decrease from the porosity of the first base material and the second base material was observed. From this, it has been clarified that the connection portion has higher density than the first member and the second member.

2.2 Evaluation of flexural strength Next, the flexural strength was measured for the reinforcing fiber composites of the examples and comparative examples by a method based on the JIS K 7074-1988 A method.

In addition, the position of the indenter in the three-point bending test was adjusted to the connection part. The measurement temperature was 25 ° C.
The measurement results are shown in Table 1. The measurement result was an average value of 5 measurements.

2.3 Evaluation of Flexural Modulus Next, the flexural modulus of each of the reinforcing fiber composites of each Example and each Comparative Example was measured by a method based on JIS K7074-1988.

The measurement temperature was 25 ° C.
The measurement results are shown in Table 1. The measurement result was an average value of 5 measurements.

  As is clear from Tables 1 and 2, it was recognized that the reinforcing fiber composites of the respective examples had relatively high bending strength and bending elastic modulus. In addition, in the reinforced fiber composite material of each comparative example, since the bending elastic modulus was too small, it was not able to measure.

  On the other hand, among the reinforcing fiber composite materials of the respective examples, the portions (first member and second member) other than the connection portion maintained a relatively large porosity that is comparable to the porosity of the base material. For this reason, even if the reinforced fiber composite material of each Example included the connection part, it was recognized that the bending strength with respect to specific gravity and a bending elastic modulus are large.

DESCRIPTION OF SYMBOLS 1 Reinforcement fiber composite material 1 'Reinforcement fiber composite material 2 1st member 3 2nd member 4 Connection part 20 1st preform | base_material 20a 1st papermaking body shape 21 1st resin 22 1st fiber 23 Hole 30 30 2nd preform | base_material 31 Second resin 32 Second fiber 33 Hole 40 Third base material 41 First high density portion 42 Second high density portion 43 Interface 44 Interface 45 Interface 46 Interface 47 Interface 50 Fourth base material 51 Dispersion medium 52 Microcapsule 61 First 1 Dispersion 70 Container 71 Filter 72 Mold 74 Mold 38 75 Mold 76 Spacer 201 Part 202 Other part 301 Part 302 Other part 721 Cavity

Claims (9)

A first member containing a first fiber and a first resin;
A second member containing a second fiber and a second resin;
A connecting portion to which the first member and the second member are connected;
Have
The reinforcing fiber composite material, wherein the density of the connection portion is higher than the density of the first member and the density of the second member.   The reinforcing fiber composite material according to claim 1, wherein the first member includes holes.   The reinforcing fiber composite material according to claim 2, wherein the second member includes pores.   The connection portion includes the first fiber and the first resin, the first high-density portion having a higher density than the first member, the second fiber, and the second resin. The reinforcing fiber composite material according to claim 3, comprising a second high-density portion having a density higher than that of the member.   The area of the interface between the first high-density part and the second high-density part is the area of the interface between the first member and the first high-density part and between the second member and the second high-density part. The reinforcing fiber composite material according to claim 4, wherein the reinforcing fiber composite material is larger than an area of the interface.   The reinforcing fiber composite material according to any one of claims 1 to 5, wherein one of the second member and the connecting portion includes a concave portion, and the other includes a convex portion that fits into the concave portion.   The reinforcing fiber composite material according to any one of claims 1 to 6, wherein at least one of the first member and the second member is a papermaking body. Preparing a first base material containing a first fiber and a first resin, and a second base material containing a second fiber and a second resin;
A connecting portion formed by compressing a part of the first base material and a part of the second base material, and connecting a part of the first base material and a part of the second base material; Obtaining a step;
The manufacturing method of the reinforced fiber composite material characterized by having.   The reinforcing fiber according to claim 8, wherein the step of preparing the first base material and the second base material is a step of producing the first base material and the second base material by a papermaking method including a foaming process. A method of manufacturing a composite material.

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