JP2018534183A - 複合体オーバーラップツールのための熱可塑性複合体インサイチュー溶融処理方法 - Google Patents
複合体オーバーラップツールのための熱可塑性複合体インサイチュー溶融処理方法 Download PDFInfo
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- JP2018534183A JP2018534183A JP2018543005A JP2018543005A JP2018534183A JP 2018534183 A JP2018534183 A JP 2018534183A JP 2018543005 A JP2018543005 A JP 2018543005A JP 2018543005 A JP2018543005 A JP 2018543005A JP 2018534183 A JP2018534183 A JP 2018534183A
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- fiber
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- thermoplastic resin
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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Abstract
Description
本出願は、参照によりその全体が本明細書に組み込まれる、2015年11月2日に出願された米国仮特許出願第62/249,467号の利益を主張する。
適用なし
1.発明の分野
本発明は、ツールを覆って繊維樹脂複合体をオーバーラップする方法に関する。より詳細には、本発明は、繊維と樹脂とを組み合わせ、圧力容器のような加熱されたツールに溶融繊維樹脂複合体を1回の連続操作で適用するインサイチュー(in−situ:現場での)溶融プロセスに関する。
炭素繊維および樹脂の複合体の分野では、鋼よりも炭素繊維の強度対重量比がより高いため、コンクリート杭、航空機翼および胴体、自動車用途およびスポーツ用品などの多数のツールおよび構造部品について、鋼から炭素繊維および樹脂複合体への置換がますます増えている。複合体がオーバーラップされた圧力容器(「COPV」)は、炭素繊維複合体の技術を利用する構造体の1つである。そして、今日市場には多数のCOPV設計があることが知られている。これに関して、タイプIIの圧力容器は、通常は鋼製である金属製のライナーの上に繊維のフープ(hoop)ラップを利用する。タイプIIIの圧力容器は、金属製のライナー(通常はアルミニウム製ライナー)上に繊維のフープと螺旋状ラップの両方を利用する。タイプIVの圧力容器は、プラスチックライナーの上にフープおよび螺旋状ラップを利用する。そして、タイプVの圧力容器は、ガス透過を防止するためにバリアフィルムを組み込むことができるライナーレスツール上にフープおよび螺旋状繊維ラップを利用する。本発明は、本明細書で説明するように、これらのタイプの圧力容器内での有用性を有するが、複合体オーバーラップを利用する他のタイプのツールにおいても有用性を有する。これらの設計の大部分は、炭素繊維および熱硬化性樹脂を用いた従来の湿式巻取り(winding)プロセスを使用する。そして、今日タンクを製造するために使用される現在の材料およびプロセスは、費用がかかり、労力を要することはよく知られている。
・繊維/樹脂複合体を形成するいくつかの既知の方法の1つを選択する。
・繊維/樹脂複合体を圧力容器本体上に巻き取る。
・Bステージに達するまで圧力容器を回転させる。
・オーブン中、高められた温度でシリンダーを硬化させる。
・シリンダーおよびパッケージを清掃する。
本発明は、圧力容器のために使用されるような炭素繊維オーバーラップを製造する方法に関する。当業者であれば、本明細書では一般的に加工対象物と称される他のタイプの物品がしばしば繊維樹脂複合体でオーバーラップされることを認識するであろう。本発明はさらに、フィラメント巻取り機の配送ヘッド、自動テープ敷設システムの配送ヘッド、またはトウ敷設システムの配送ヘッドにおいて、繊維および熱可塑性樹脂の両方を組み合わせ、そして限定するものではないが、圧力容器などの加熱された加工対象物に溶融した繊維熱可塑性樹脂複合体を適用するためのインサイチュー(in−situ:現場の)プロセスの使用に向けられている。
Claims (18)
- 繊維樹脂複合体オーバーラップを製造するためのインサイチュー(in−situ)溶融プロセスであって、
繊維トウを選択するステップ、
前記の選択された繊維トウと適合性がある熱可塑性樹脂を選択するステップ、
前記の選択された熱可塑性樹脂による含侵のため前記繊維トウを調製するステップ、
前記繊維トウ中への含侵のために前記熱可塑性樹脂を調製するステップ、
フィラメント巻取りヘッドの直近で、前記の調製された繊維トウ中に前記の調製された熱可塑性樹脂を含侵させ、それによって溶融繊維トウプレグを形成するステップ、
前記の溶融繊維トウプレグを、加工対象物の加熱表面に適用し、それにより、ラッピング操作の間、前記の溶融繊維トウプレグの溶融状態が維持され、それによって前記の溶融した複合体がより効率的に加工対象物の加熱表面に付着し、連続的な溶融複合体の複数層がお互いにより良好に付着することになり、さらに個々のフィラメントが互いに対してスライドすることが可能になり、複合体の内部でカテナリー、しわ、および折り目を効率的に除去するステップ、ならびに
加圧下で前記の溶融繊維トウプレグの複数層を互いに押圧し、圧密化し、それによって閉じ込められた空気を除くステップを含む、上記インサイチュー溶融プロセス。 - 前記加工対象物がタイプII圧力容器である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記加工対象物がタイプIII圧力容器である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記加工対象物がタイプIV圧力容器である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記加工対象物がタイプV圧力容器である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記繊維が、炭素繊維、ガラス繊維、天然繊維、ナノファイバー、およびアラミド繊維からなる群から選択される、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、ナイロン樹脂、ポリプロピレン樹脂、ポリエチレン樹脂、およびポリエーテルエーテルケトン樹脂からなる群から選択される、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、ペレット形状である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、テープ形状である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、スレッド形状である、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂による含侵のため前記繊維トウを調製するステップが、前記繊維トウを乾燥するステップ、前記繊維トウを選択されたバンド幅に拡幅するステップ、および、前記繊維トウを選択された温度に加熱するステップであって、前記選択された温度が前記の選択された熱可塑性樹脂の融点に近い加熱ステップを含む、請求項1に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 繊維樹脂複合体オーバーラップを製造するためのインサイチュー(in−situ)溶融プロセスであって、
繊維トウを選択するステップ、
前記の選択された繊維トウと適合性がある熱可塑性樹脂を選択するステップ、
前記の選択された熱可塑性樹脂による含侵のため前記繊維トウを調製するステップであって、前記繊維トウを乾燥するステップ、前記繊維トウを選択されたバンド幅に拡幅するステップ、および、前記繊維トウを選択された温度に加熱するステップであって、前記選択された温度が前記の選択された熱可塑性樹脂の融点に近い加熱ステップを含む、繊維トウ調製ステップ
前記繊維トウ中への含侵のために前記熱可塑性樹脂を調製するステップ、
フィラメントの巻取りヘッドの直近で、前記の調製された繊維トウ中に前記の調製された熱可塑性樹脂を含侵させ、それによって溶融繊維トウプレグを形成するステップ、
前記の溶融繊維トウプレグを、加工対象物の加熱表面に適用し、それにより、ラッピング操作の間、前記の溶融繊維トウプレグの溶融状態が維持され、それによって前記の溶融した複合体がより効率的に加工対象物の加熱表面に付着し、連続的な溶融複合体の複数層がお互いにより良好に付着することになり、さらに個々のフィラメントが互いに対してスライドすることが可能になり、複合体の内部でカテナリー、しわ、および折り目を効率的に除去するステップ、ならびに
加圧下で前記の溶融繊維トウプレグの複数層を互いに押圧し、圧密化し、それによって閉じ込められた空気を除くステップを含む、上記インサイチュー溶融プロセス。 - 前記加工対象物が、タイプII圧力容器、タイプIII圧力容器、タイプIV圧力容器、およびタイプV圧力容器からなる群から選択される、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記繊維が、炭素繊維、ガラス繊維、天然繊維、ナノファイバー、およびアラミド繊維からなる群から選択される、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、ナイロン樹脂、ポリプロピレン樹脂、ポリエチレン樹脂、およびポリエーテルエーテルケトン樹脂からなる群から選択される、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、ペレット形状である、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、テープ形状である、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
- 前記熱可塑性樹脂が、スレッド形状である、請求項12に記載の繊維樹脂複合体オーバーラップを製造するためのインサイチュー溶融プロセス。
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CN109763279B (zh) * | 2019-03-06 | 2021-11-02 | 佛山市石金科技有限公司 | 一种碳纤维加工出料装置 |
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