JP5686994B2 - 成形体の製造方法 - Google Patents
成形体の製造方法 Download PDFInfo
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- JP5686994B2 JP5686994B2 JP2010151218A JP2010151218A JP5686994B2 JP 5686994 B2 JP5686994 B2 JP 5686994B2 JP 2010151218 A JP2010151218 A JP 2010151218A JP 2010151218 A JP2010151218 A JP 2010151218A JP 5686994 B2 JP5686994 B2 JP 5686994B2
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- 238000001723 curing Methods 0.000 description 77
- 238000010438 heat treatment Methods 0.000 description 22
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 22
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Laminated Bodies (AREA)
Description
図10に、従来の成形体の製造方法で製造された成形体10の要部の断面図を示す。マトリックス4aが炭素発泡体2の内部に浸透すると、複合材料4に含まれるマトリックス量が減少するため、積層板の板厚は減少し、繊維が露出することもある。表面に繊維が露出した状態の複合材料4では、複合材料内部にも空隙5が発生している。このような場合、複合材料の表面を機械加工したとしても、ツール面の平滑度が要求値を満たせず、成形治具として使用できないといった問題があった。
多孔体上で、予め接着剤を硬化させておくことで、多孔体表層に存在する孔をある程度塞ぐことができる。その上で更に接着剤を硬化させるため、多孔体と複合材料との間に、より確実に接着剤の層を形成させることができるようになる。このようにすることで、硬化後の複合材料の表面がより平滑となる。
このようにすることで、接着剤及び複合材料の硬化反応を一連の工程で処理できるようになるため、作業労力の軽減及び作業時間の短縮に繋がる。
以下に、本発明に係る成形体の製造方法の一実施形態について説明する。以下の実施形態において、成形体1は、構造物を複合材料で製造するために使用する成形治具とされるが、これに限定されるものではない。
多孔体2は、高い剛性を有するのが好ましく、炭素発泡体などとされる。本実施形態では、CFOAM20(Touchstone Research Laboratory製)が用いられる。
まず、炭素発泡体上の所定の場所にフィルム接着剤を配置する。フィルム接着剤は、複数重ねて配置することが好ましい。
なお、フィルム接着剤の上に、ピールプライ、離型フィルム、及びブリーザークロスなどを重ねてからバッグフィルムで覆っても良い。
なお、複合材料の下に、未硬化の接着剤を配置して、複合材料と共に硬化させても良い。
本実施形態において、成形体は、第1実施形態と同様の構成とする。
本実施形態に係る成形体の製造方法は、接着剤を硬化させる工程が異なる以外は、第1実施形態と同様とする。
(1)接着剤の粘度プロファイルを取得するステップ
(2)接着剤が硬化するときの熱量データを取得して、該熱量データから接着剤の硬化反応式を作成するステップ
(3)接着剤の粘度プロファイルと、硬化反応式とを相関させて接着剤の所定の硬化度を設定するステップ
(4)硬化反応式に基づいて、所定の硬化度以上となるよう接着剤の硬化反応条件を設定するステップ
(5)接着剤を少なくとも所定の硬化度まで硬化させるステップ
硬化反応は式(A)で表される。
dα/dt=f(α,T)・・・(A)
ここで、αは硬化度、tは時間、Tは温度である。
dα/dt=k1(1−α)l+k2αm(1−α)n・・・(B)
ki=Ai・exp(−Ei/RT)・・・(C)
ここで、Aは頻度因子、Eは活性化エネルギー、kは反応速度定数である。
本実施形態において、成形体は、第1実施形態と同様の構成とする。
本実施形態に係る成形体の製造方法は、まず、炭素発泡体上の所定の場所にフィルム接着剤を配置する。フィルム接着剤は、複数重ねて配置することが好ましい。
なお、フィルム接着剤の上に、ピールプライ、離型フィルム、及びブリーザークロスなどを重ねてからバッグフィルムで覆っても良い。
複合材料を所定の昇温速度で加熱し、粘度プロファイルを測定した(不図示)。複合材料は、初期段階では温度上昇にともない軟化されるが、硬化開始温度に達すると、一転して粘度が上昇した。TRK510/270FMPの硬化開始温度は、140℃付近だった。TRK510/270FMPは、約100℃を超えると液状化された。「液状化」とは、マトリックスの粘度が2Pa・s以下で,オートクレーブ加圧により多孔体に圧入されやすくなる粘度である状態を意味する。
接着剤の硬化反応の加熱温度及び反応時間は、所定の硬化度を0.25として、式(B)及び式(C)から導き出す。
2 多孔体
3 接着剤
4 複合材料
5 空隙
Claims (3)
- 多孔体上に、熱硬化性の接着剤を配置する工程と、
前記接着剤の上に、熱硬化性樹脂をマトリックスとする複合材料を配置する工程と、
前記接着剤を硬化させる工程と、
前記接着剤を硬化させた後に、前記複合材料のマトリックスを液状化及び硬化させる工程と、
を備え、
前記接着剤を硬化させる工程が、
前記接着剤の粘度プロファイルを取得するステップと、
前記接着剤が硬化するときの熱量データを取得して、該熱量データから前記接着剤の硬化反応式を作成するステップと、
前記接着剤の粘度プロファイルと、前記硬化反応式とを相関させて前記接着剤の所定の硬化度を設定するステップと、
前記硬化反応式に基づいて、前記所定の硬化度以上となるよう前記接着剤の硬化反応条件を設定するステップと、
前記接着剤を少なくとも所定の硬化度まで硬化させるステップと、
を含む成形体の製造方法。 - 前記硬化させた接着剤の上に、更に未硬化の接着剤及び前記複合材料を順に配置した後、前記複合材料を液状化及び硬化させる請求項1に記載の成形体の製造方法。
- 前記接着剤を硬化させる工程が、
前記複合材料の粘度プロファイルを取得するステップを更に備え、
前記複合材料の粘度プロファイル及び前記硬化反応式に基づいて、前記所定の硬化度以上となるよう前記接着剤の硬化反応条件を設定し、
前記多孔体上に前記接着剤及び前記複合材料を順に配置した後、前記接着剤を硬化させる請求項1に記載の成形体の製造方法。
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