JP5315692B2 - 繊維強化プラスチックの製造方法 - Google Patents
繊維強化プラスチックの製造方法 Download PDFInfo
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- JP5315692B2 JP5315692B2 JP2007522336A JP2007522336A JP5315692B2 JP 5315692 B2 JP5315692 B2 JP 5315692B2 JP 2007522336 A JP2007522336 A JP 2007522336A JP 2007522336 A JP2007522336 A JP 2007522336A JP 5315692 B2 JP5315692 B2 JP 5315692B2
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- plate
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- protrusion
- reinforcing fibers
- reinforced plastic
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- Chemical & Material Sciences (AREA)
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- Inorganic Chemistry (AREA)
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Description
(a)それぞれの繊維長が10乃至100mmの多数本の強化繊維が一方向に順次配列された強化繊維シートと該強化繊維シートの全体に、あるいは、部分的に含浸した未硬化状態のマトリックス樹脂とからなる少なくとも2枚のプリプレグ基材が、前記強化繊維の配列方向が異なる状態で積層されてなるプリプレグ積層体を用意する積層体準備工程と、
(b)前記突起部を形成するための凹部を有する一方の金型と、該金型との間で前記板状部を形成する他方の金型とからなる前記板状体を成形する成形装置を用意する成形装置準備工程と、
(c)前記成形装置準備工程において用意された前記成形装置の前記金型間に、前記積層体準備工程において用意された前記プリプレグ積層体を収容する積層体収容工程と、
(d)前記積層体収容工程において前記金型内に収容された前記プリプレグ積層体を、前記金型により加熱および加圧し、前記プリプレグ積層体を積層状態を保ったまま、積層面の方向に流動させて前記板状部の賦形を行い、かつ積層面の方向に対し面外方向に流動させて前記突起部の賦形を行うとともに、前記マトリクス樹脂の固化を行い前記板状体を形成する板状体形成工程と、
(e)前記板状体形成工程において形成された板状体を、前記金型から取り出す板状体脱型工程とからなる繊維強化プラスチックの製造方法。
1a、1b: 板状部
1t: 板状部の厚み
2a: 突起部
2aS1、2aS2、2aS3: 突起部における面
2h: 突起部の高さ
2t: 突起部の厚み
3a−3h: マトリックス樹脂が共存した強化繊維層
4: 強化繊維
4A2a、4B2a、4C2a: 突起部
5: 板状体
5a−5d: 積層されたプリプレグ基材における強化繊維層
6: 樹脂領域
7a−7k: 突起部外表面を形成している面
8a−8o: 突起部におけるマトリックス樹脂が共存した強化繊維層
9: 繊維長手方向
10: 繊維直交方向
11: 一方向プリプレグシート
12: 切り込み
13、13A、13B: 上金型
14、14A1、14A2、14B1、14B2: リブ溝
51a、51b: 板状部
52a: 突起部
101: 板状体
111: 板状体
Tp−60≦T≦Tp+20 ・・・(I)
を満足する条件で製造されることが好ましい。次の関係式(II)
Tp−30≦T≦Tp ・・・(II)
を満足することが、更に好ましい。
次の手順にてエポキシ樹脂組成物を得た。
3点曲げ試験による曲げ剛性測定により力学特性を評価した。リブを有する成形体より、リブが、試験片長手方向に連続し、かつ、試験片中央部となるように、長さ100±1mm、幅30±0.2mmの形状に切り出し試験片を得た。
上記のプリプレグの作製方法により、図6に示す一方向プリプレグシート11を用意した。図6において、この一方向プリプレグシート11における多数本の強化繊維の配列方向(繊維長手方向)が、矢印9(図6において上下方向)で示され、強化繊維の配列方向に直交する方向(繊維直交方向)が、矢印10(図6において、左右方向)で示される。一方向プリプレグシート11に、自動裁断機を用いて、図6に示すような等間隔で規則的な切り込み12を、繊維直交方向に連続的に挿入した。図6において、各切り込みの幅aは、10mmであり、繊維長手方向における各切り込み間隔(ピッチ)b、すなわち、強化繊維の分断された長さは、30mmであり、繊維直交方向において隣接する切り込み間の間隔cは、10mmとした。
上金型の突起部形成用の溝の位置を、図9に示す十字形状の溝14B1、14B2に変更した上金型13Bを用いた以外は、実施例1と同様にして、成形体(板状体)を作製した。
一方向プリプレグシートに切り込みを挿入しないこと以外は、実施例1と同様にして、平板状の成形体(板状体)を得た。
突起部形成用の溝を有さない上金型を用いた以外は、実施例1と同様にして、平板状の成形体(板状体)を得た。
実施例1において用意したプリプレグ基材を、[+45/0/−45/90]2となるように、8枚積層し、プリプレグ積層体Aを作製した。作製したプリプレグ積層体Aから、300×20mmの大きさのプリプレグ積層体Bを、2体切り出した。
実施例1で用いた一方向プリプレグシートと同様の炭素繊維(フィラメント数12,000本)、および、エポキシ樹脂組成物を用いて、繊維長25mm、炭素繊維目付750g/m2、樹脂重量分率50%のSMCシートを作製した。SMCシートを300×300mmの大きさに切り出し、それらを2枚積層し、実施例1と同様の条件により、2本の直線状のリブを有する平板状の成形体(板状体)を作製した。
Claims (7)
- 板状部と該板状部の少なくとも片側の面から隆起した突起部を有する板状体からなり、前記板状部および突起部が、多数本の強化繊維と、該多数本の強化繊維と一体となったマトリックス樹脂とからなる繊維強化プラスチックの製造方法において、
(a)それぞれの繊維長が10乃至100mmの多数本の強化繊維が一方向に順次配列された強化繊維シートと該強化繊維シートの全体に、あるいは、部分的に含浸した未硬化状態のマトリックス樹脂とからなる少なくとも2枚のプリプレグ基材が、前記強化繊維の配列方向が異なる状態で積層されてなるプリプレグ積層体を用意する積層体準備工程と、
(b)前記突起部を形成するための凹部を有する一方の金型と、該金型との間で前記板状部を形成する他方の金型とからなる前記板状体を成形する成形装置を用意する成形装置準備工程と、
(c)前記成形装置準備工程において用意された前記成形装置の前記金型間に、前記積層体準備工程において用意された前記プリプレグ積層体を収容する積層体収容工程と、
(d)前記積層体収容工程において前記金型内に収容された前記プリプレグ積層体を、前記金型により加熱および加圧し、前記プリプレグ積層体を積層状態を保ったまま、積層面の方向に流動させて前記板状部の賦形を行い、かつ積層面の方向に対し面外方向に流動させて前記突起部の賦形を行うとともに、前記マトリクス樹脂の固化を行い前記板状体を形成する板状体形成工程と、
(e)前記板状体形成工程において形成された板状体を、前記金型から取り出す板状体脱型工程とからなる繊維強化プラスチックの製造方法。 - 前記プリプレグ積層体が、前記突起部が形成される面とは反対側の面において一体化された強化繊維基層を含み、かつ、該強化繊維基層における強化繊維が、多数本の連続した強化繊維からなる請求項1に記載の繊維強化プラスチックの製造方法。
- 前記マトリックス樹脂が、熱硬化性樹脂である請求項1に記載の繊維強化プラスチックの製造方法。
- 前記金型の温度が一定に維持されている間に、前記板状体形成工程と前記板状体脱型工程が行われる請求項3に記載の繊維強化プラスチックの製造方法。
- 前記板状体形成工程における前記熱硬化性樹脂の粘度が、0.1乃至100Pa・sである請求項3に記載の繊維強化プラスチックの製造方法。
- 前記板状体形成工程における前記金型の温度Tと前記熱硬化性樹脂の発熱ピーク温度Tpとが、Tp−60≦T≦Tp+20の関係を満足する請求項3に記載の繊維強化プラスチックの製造方法。
- 前記積層体準備工程で用意される前記プリプレグ積層体に関して、前記10乃至100mmの繊維長が、一方向に配列された多数本の強化繊維に、この長さの間隔で、順次、切り込みを入れることにより創出されており、かつ、少なくとも隣接して位置する前記プリプレグ基材間で、前記切り込みの位置および方向の一方あるいは双方が異なっている請求項1に記載の繊維強化プラスチックの製造方法。
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EP2067615A1 (en) | 2009-06-10 |
EP2067615A4 (en) | 2012-04-04 |
EP2067615B1 (en) | 2016-11-16 |
ES2606394T3 (es) | 2017-03-23 |
WO2008038429A1 (en) | 2008-04-03 |
TWI415738B (zh) | 2013-11-21 |
JPWO2008038429A1 (ja) | 2010-01-28 |
KR101286085B1 (ko) | 2013-07-15 |
KR20090071537A (ko) | 2009-07-01 |
US8101262B2 (en) | 2012-01-24 |
US20100028616A1 (en) | 2010-02-04 |
CN101516613B (zh) | 2013-05-08 |
TW200815183A (en) | 2008-04-01 |
CN101516613A (zh) | 2009-08-26 |
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