JP2020515442A - 平らな複合部材を製造する方法およびそれにより製造された複合部材 - Google Patents
平らな複合部材を製造する方法およびそれにより製造された複合部材 Download PDFInfo
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- JP2020515442A JP2020515442A JP2019554512A JP2019554512A JP2020515442A JP 2020515442 A JP2020515442 A JP 2020515442A JP 2019554512 A JP2019554512 A JP 2019554512A JP 2019554512 A JP2019554512 A JP 2019554512A JP 2020515442 A JP2020515442 A JP 2020515442A
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Abstract
Description
例えば特許文献1には、発泡体コアを有する複合部材であって、発泡体コアの表面において両側に、発泡体コアと材料間接合により結合したカバー層が配置されている、発泡体コアを有する複合部材について記載されている。複合部材を製造するために、カバー層および発泡体コアが加熱され、その後、カバー層が発泡体コアの表面に配置され、これらすべてが、完成品の複合部材を形成するプレス機または鋳型に入れられる。また、加熱は鋳型内で初めて行われてもよい。続いて、発泡体コアおよびカバー層が成形され、所定の成形時間の後に再び冷却され、発泡体コアとカバー層とが材料間接合により結合される。カバー層としては金属カバー層が記載されており、特にアルミニウムから形成されるが記載されている。代替例として繊維強化プラスチックから形成されるカバー層も記載されている。記載の方法は、成形工程の間にカバー層を発泡体コアの表面にずらすことが可能であることにより、特に複合形態を有する非平面型複合部材の製造にとって有利であると示されている。
A.20〜60重量%のガラス含量と5体積%未満の空隙率とを有する、ガラス繊維強化ポリプロピレンから形成される厚さ0.5〜5mmの1つまたは2つのカバー層と、
B.35〜80重量%のガラス含量と20〜80体積%の空隙率とを有する、ガラス繊維強化ポリプロピレンから形成される厚さ2〜40mmのコア層と
を含む、曲げに強い複合板に関する。
コア層を用意する工程:1)不織布製造、2)強化繊維を熱プレス機内で含浸(圧力&温度下)、3)冷却プレス機内での固化;
カバー層を用意する工程:1)マット製造、2)押出成形、3)熱プレス機内で含浸、4)冷却プレス機内での固化;
複合板を製造する工程:1)熱プレス機内でのカバー膜およびコア膜の加熱、2)カバー膜&コア膜の冷却
が必要である。
コア層を用意する工程:1)マット製造、2)溶融物層をマットに押出成形、3)強化繊維を熱プレス機内で含浸(圧力&温度下)、4)冷却プレス機内での固化、5)固化したコア層の加熱、これらの膨張、6)コア層の冷却;
カバー層を用意する工程:1)マット製造、2)押出成形、3)熱プレス機内での含浸、4)冷却プレス機内での固化;
複合板を製造する工程:1)カバー層の加熱、2)カバー層と冷たいコア層との一緒のプレス;
が必要であり、そのため、製造は平板に限定されており、3D部材については、コアを予めさらなる工程で相応して成形し、続いて、カバー膜と一緒にプレスする必要がある。
2つのカバー層(A、A’)の間に配置され材料間接合によりこれらのカバー層と結合したコア層(B)を有し、カバー層がカバー層熱可塑性樹脂を含有し、コア層がコア層熱可塑性樹脂を含有する、平らな複合部材を製造する本発明の方法は、
a)両カバー層およびコア層の相応する素材(ブランク)を用意し、これらの素材から、カバー層熱可塑性樹脂およびコア層熱可塑性樹脂の双方の融点を超える温度に加熱された層順序A−B−A’の積層体を形成する工程と、
b)加熱された積層体(A−B−A’)をプレスする工程と、
c)プレスされた積層体を冷却して、固化され材料間接合により互いに結合した層を有する平らな複合部材を形成する工程と、
を含む。
工程a)において、コア層(B)の予め用意した素材が、強化繊維とコア層熱可塑性樹脂の熱可塑性樹脂繊維とから形成された、単位面積当たりの重量が500〜10000g/m2の少なくとも1つのランダム配向繊維不織布層(D)を含み、
工程c)の後に、固化したカバー層が5体積%未満の空隙率を有し、固化したコア層が20〜80体積%の空隙率を有することにより、本発明による方法から様々な利点が得られる。
コア膜を用意する工程:1)ランダム配向繊維不織布を製造;
カバー膜を用意する工程:1)好適には織物による繊維不織布製造;
複合部材を製造する工程:1)バリオサームプレス金型内で加熱および冷却(1回の工程)
しか必要とされない。
本方法の有利な実施形態(請求項5)によると、工程a)において、用意した両カバー層(A、A’)およびコア層(B)の素材は、冷たい状態において層順序A−B−A’で互いに積層化され、そのようにして形成された積層体(A−B−A’)は、カバー層熱可塑性樹脂およびコア層熱可塑性樹脂の双方の融点を超える温度に加熱される。すなわち、この実施形態の場合、冷たい素材から出発して、まず積層体A−B−Aが構築され、全体的に加熱される。続いて、加熱された積層体は、工程b)でプレス金型内にてプレスされ、工程c)で冷却される。プレス金型の形状は、製造すべき部材の所望の形状に応じて選択される。この実施形態の場合、カバー層熱可塑性樹脂およびコア層熱可塑性樹脂は、それらの熱可塑変形が適切な温度範囲で同時に可能であるように、互いに適合している必要がある。方法を実施するために、例えば、組み合わされた加熱、プレスおよび冷却ステーションを使用してもよい(いわゆるバリオサーム法)。しかしながら、加熱処理を独立した接触式加熱ステーションで実施し、続いて下流のプレス装置内でプレスおよび冷却することも可能である。本方法の有利なさらなる形態(請求項6)によると、カバー層熱可塑性樹脂およびコア層熱可塑性樹脂は同一である。それにより、個々の層同士の接着は、互いに材料間接合により、かつさらなる接着フィルムまたは接着剤なしで行われる。
本方法の有利な実施形態(請求項12)によると、加熱された積層体のプレスは、非平面型のプレス金型内で実施される。それにより、様々な種類の3次元構造の平らな複合部材が製造される。
本発明の実施例について、以下で図面を用いてより詳細に説明する。
カバー層Aの可能な形態が図2に示されている。予め用意した形態においてこの層は、繊維不織布層C、および繊維不織布層Cとニードルパンチされた、強化繊維から形成される織物層Eを含む。そのような層は、例えば、層CおよびEを互いに隣接させることおよびニードルパンチすることにより製造されてもよく、ニードルパンチの場合、不織布繊維Cの一部に強化繊維層Eが貫通する。それに相応して、強化繊維層Eは、両側で不織布繊維Cに囲まれている。
図4に示される複合部材において、固化していない形態にあるコア層Bは、両側において、ランダム配向繊維不織布層Dの内側に配置された構造層Fを、異なる強化繊維割合を有するハニカム板またはランダム配向繊維層の形態で有する。示される例において、構造層は面全体に形成されており、よって、サンドウィッチ状に2つのランダム配向繊維層の間に埋め込まれている。
以下の表は、熱可塑性樹脂およびガラス繊維(GF)としてのPPおよびPEEK、ならびに強化繊維としての炭素繊維(CF)の様々な組み合わせについての関連する値の一覧を示しており、
VF 繊維の体積割合
WF 繊維の重量割合
WP ポリマーの重量割合
DF 繊維の密度(kg/m3)
DP ポリマーの密度(kg/m3)。
DC 複合材の密度(kg/m3)。
tC 複合材の厚さ(m)
AC 複合材の単位面積当たりの重量。
本発明による曲げに強い層構造A−B−Aの複合部材を製造した。炭素繊維織物とPEI熱可塑性樹脂繊維とを有する単位面積当たりの重量が440g/m2の繊維不織布素材から両カバー層Aを用意した。PEI熱可塑性樹脂繊維を有する炭素繊維から形成される、単位面積当たりの重量が4×500g/m2である合計4つの膜のランダム配向繊維不織布からコア層Bを用意した。
実施例3…異なる厚さの領域を有する複合部材
本発明による曲げに強い層構造A−B−Aの複合部材を製造した。炭素繊維織物とPEI熱可塑性樹脂繊維とを有する単位面積当たりの重量が440g/m2の繊維不織布素材から両カバー層Aを用意した。PEI熱可塑性樹脂繊維を有する炭素繊維から形成される単位面積当たりの重量が7×500g/m2である合計7つの膜のランダム配向繊維不織布からコア層Bを用意した。
以下の表は、本発明による様々な複合部材について測定した機械的特性を示す。
Claims (16)
- 2つのカバー層(A、A’)の間に配置され材料間接合により前記カバー層と結合したコア層(B)を有し、前記カバー層がカバー層熱可塑性樹脂を含有し、前記コア層がコア層熱可塑性樹脂を含有する、平らな複合部材を製造する方法であって、
a)両カバー層およびコア層の相応する素材を用意し、前記素材から、前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂の双方の融点を超える温度に加熱された層順序A−B−A’の積層体を形成する工程と、
b)加熱された前記積層体(A−B−A’)をプレスする工程と、
c)プレスされた前記積層体を冷却して、固化され材料間接合により互いに結合した層を有する前記平らな複合部材を形成する工程とを含み、
工程a)において、両カバー層(A、A’)の予め用意した素材が、固化していない柔軟な形態で予め装入され、少なくとも一方のカバー層(A)が、前記カバー層熱可塑性樹脂の熱可塑性樹脂繊維10〜100重量%と強化繊維0〜90重量%とから形成される、単位面積当たりの重量が300〜3000g/m2の固化していない柔軟な繊維不織布層(C)を含み、
工程a)において、前記コア層(B)の予め用意した素材が、強化繊維と前記コア層熱可塑性樹脂の熱可塑性樹脂繊維とから形成された、単位面積当たりの重量が500〜10000g/m2の少なくとも1つのランダム配向繊維不織布層(D)を含み、
工程c)の後に、固化したカバー層が5体積%未満の空隙率を有し、固化したコア層が20〜80体積%の空隙率を有する
ことを特徴とする方法。 - 工程a)で用意した前記コア層(B)の前記ランダム配向繊維不織布層(D)が、ニードルパンチされている、請求項1に記載の方法。
- 前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂が、PP、PEI、PEEK、PPS、PA、PEAK、PEKKおよびPCから独立して選択される、請求項1または2に記載の方法。
- 前記強化繊維が、炭素繊維、ガラス繊維、アラミド繊維、バサルト繊維および高溶融熱可塑性樹脂繊維から選択される、請求項1乃至3のいずれか1項に記載の方法。
- 工程a)において、両カバー層(A、A’)および前記コア層(B)の素材が、冷たい状態において前記層順序A−B−A’で互いに積層化され、そのようにして形成された前記積層体(A−B−A’)が、前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂の双方の融点を超える温度に加熱され、加熱された積層体(A−B−A’)が形成され、次いでプレス工程b)が実施される、請求項1乃至4のいずれか1項に記載の方法。
- 前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂が同一である、請求項5に記載の方法。
- 工程a)において、前記コア層(B)の前記素材および前記カバー層(A、A’)の前記素材が、互いに独立して、対応する熱可塑性樹脂の融点を超える温度に加熱され、その後、加熱された状態にて前記層順序A−B−A’で互いに積層化されて加熱された積層体(A−B−A’)が形成され、次いでプレス工程b)が実施される、請求項1乃至4のいずれか1項に記載の方法。
- 固化していない形態にある少なくとも1つの前記カバー層(A)は、前記繊維不織布層(C)とニードルパンチまたは縫合または熱的結合された、単位面積当たりの重量が100〜2000g/m2の、強化繊維から形成される織物層またはスクリム層(E)を有する、請求項1乃至7のいずれか1項に記載の方法。
- 少なくとも1つの前記カバー層(A)が、異なる強化繊維材料から形成される複数の織物層またはスクリム層(E1、E2など)を有する、請求項8に記載の方法。
- 固化していない形態にある前記コア層(B)が、前記ランダム配向繊維不織布層(D)に隣接した少なくとも1つのさらなる構造層(F)、特に、異なる強化繊維割合を有するさらなるランダム配向繊維不織布層またはハニカム層もしくは発泡材層を有する、請求項1乃至9のいずれか1項に記載の方法。
- 前記構造層(F)が、前記コア層の選択された領域にのみ備えられている、請求項10記載の方法。
- 前記加熱された積層体(A−B−A’)をプレスする工程を、非平面型のプレス金型内で実施する、請求項1乃至11のいずれか1項に記載の方法。
- 請求項1乃至12のいずれか1項に記載の方法により製造され、2つのカバー層(A、A’)の間に配置され材料間接合により前記カバー層と結合したコア層(B)を有する、平らな複合部材。
- 前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂がPEEKであり、前記強化繊維が炭素繊維であり、前記カバー層(A、A’)が、1.0〜2.0g/cm3の密度、特に1.3〜1.8g/cm3の密度を有し、前記コア層(B)が、0.2〜1.0g/cm3の密度、特に0.3〜0.6g/cm3の密度を有する、請求項13に記載の平らな複合部材。
- 前記カバー層熱可塑性樹脂および前記コア層熱可塑性樹脂がPEIであり、前記強化繊維が炭素繊維であり、前記カバー層(A、A’)が、1.0〜2.0g/cm3の密度、特に1.3〜1.8g/cm3の密度を有し、前記コア層(B)が、0.2〜1.0g/cm3の密度、特に0.3〜0.6g/cm3の密度を有する、請求項13に記載の平らな複合部材。
- 請求項13乃至15のいずれか1項に記載の平らな複合部材の航空または車両製造における使用。
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WO2020094671A1 (de) | 2018-11-05 | 2020-05-14 | Mitsubishi Chemical Advanced Materials Composites Ag | Verfahren zur herstellung eines thermoplastisch verformbaren faserverstärkten flächigen halbzeugs |
EP3680097A1 (de) * | 2019-01-10 | 2020-07-15 | Quadrant Plastic Composites AG | Verfahren zur herstellung eines thermoplastisch verformbaren faserverstärkten flächigen halbzeugs |
CN115122673B (zh) * | 2021-03-29 | 2023-09-22 | 中国航发商用航空发动机有限责任公司 | 检测预制体能否满足纤维体分含量设计要求的方法 |
CN115431602B (zh) * | 2022-09-02 | 2023-09-26 | 华润化学材料科技股份有限公司 | 一种医药保温箱围板 |
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EP3606742A1 (de) | 2020-02-12 |
EP3606742B1 (de) | 2023-03-22 |
CN111201132B (zh) | 2022-10-25 |
CN111201132A (zh) | 2020-05-26 |
US11633939B2 (en) | 2023-04-25 |
EP3385069A1 (de) | 2018-10-10 |
US20210197519A1 (en) | 2021-07-01 |
JP2023002513A (ja) | 2023-01-10 |
WO2018185090A1 (de) | 2018-10-11 |
JP2024023179A (ja) | 2024-02-21 |
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