JP5694386B2 - 炭素繊維強化複合材料の接合体 - Google Patents
炭素繊維強化複合材料の接合体 Download PDFInfo
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- JP5694386B2 JP5694386B2 JP2012554825A JP2012554825A JP5694386B2 JP 5694386 B2 JP5694386 B2 JP 5694386B2 JP 2012554825 A JP2012554825 A JP 2012554825A JP 2012554825 A JP2012554825 A JP 2012554825A JP 5694386 B2 JP5694386 B2 JP 5694386B2
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- thermoplastic resin
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- carbon fiber
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims description 91
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- XMWRBQBLMFGWIX-UHFFFAOYSA-N C60 fullerene Chemical compound C12=C3C(C4=C56)=C7C8=C5C5=C9C%10=C6C6=C4C1=C1C4=C6C6=C%10C%10=C9C9=C%11C5=C8C5=C8C7=C3C3=C7C2=C1C1=C2C4=C6C4=C%10C6=C9C9=C%11C5=C5C8=C3C3=C7C1=C1C2=C4C6=C2C9=C5C3=C12 XMWRBQBLMFGWIX-UHFFFAOYSA-N 0.000 description 2
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Images
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3055—Cars
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
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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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
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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
- B32B2262/106—Carbon fibres, e.g. graphite 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
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- B32B2605/003—Interior finishings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T403/00—Joints and connections
- Y10T403/47—Molded joint
- Y10T403/477—Fusion bond, e.g., weld, etc.
Description
<1>
熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム層と、連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている一方向材層とをそれぞれ少なくとも1層ずつ有する補強材が、
ランダム層および一方向材層よりなる群から選ばれる少なくとも1つを有する、開断面形状の被補強材と中空閉断面を作るように振動溶着されており、
前記補強材は、前記ランダム層及び前記一方向材層の一方をコア材とし、他方をスキン層とした積層構造を有する、接合体。
<2>
熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム炭素繊維強化複合材料と、連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている連続炭素繊維強化複合材料とを合わせて型内にてプレスすることにより、それぞれをランダム層、一方向材層とした立体形状である補強材を使用した<1>に記載の接合体。
<3>
ランダム層に含まれるチョップド炭素繊維が繊維長10〜100mmのものである<1>又は<2>に記載の接合体。
<4>
ランダム層の全体積に対し、一方向材層が5〜100Vol%の体積にて存在する補強材を使用した<1>〜<3>のいずれかに記載の接合体。
<5>
ランダム層における熱可塑性樹脂の存在量が、チョップド炭素繊維100重量部に対し、50〜1000重量部である事を特徴とする補強材を使用した<1>〜<4>のいずれかに記載の接合体。
<6>
一方向材層における熱可塑性樹脂の存在量が、連続炭素繊維100重量部に対し、30〜200重量部である事を特徴とする補強材を使用した<1>〜<5>のいずれかに記載の接合体。
<7>
一方向材層が、連続炭素繊維を一方向に引き揃えた一方向材に熱可塑性樹脂を含浸あるいは半含浸させたものであることを特徴とする<1>〜<6>のいずれかに記載の接合体。
なお、本発明は上記<1>〜<7>に関するものであるが、参考のため下記1.〜9.項に記載した事項などのその他の事項についても記載した。
ランダム層および一方向材層よりなる群から選ばれる少なくとも1つを有する、開断面形状の被補強材と、
中空閉断面を作るように振動溶着された接合体。
2. ランダム層をコア材とし、一方向材層をスキン層とした積層構造を有する補強材を使用した上記1.項に記載の接合体。
3. 一方向材層をコア材とし、ランダム層をスキン層とした積層構造を有する補強材を使用した上記1.項に記載の接合体。
4. 熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム炭素繊維強化複合材料と、
連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている連続炭素繊維強化複合材料とを合わせて型内にてプレスすることにより、それぞれをランダム層、一方向材層とした立体形状である補強材を使用した上記1.〜3.のいずれかに記載の接合体。
5. ランダム層に含まれるチョップド炭素繊維が繊維長10〜100mmのものである上記1.〜4.項のいずれかに記載の接合体。
6. ランダム層の全体積に対し、一方向材層が5〜100Vol%の体積にて存在する補強材を使用した上記1.〜5.項のいずれかに記載の接合体。
7. ランダム層における熱可塑性樹脂の存在量が、チョップド炭素繊維100重量部に対し、50〜1000重量部である事を特徴とする補強材を使用した上記1.〜6.項のいずれかに記載の接合体。
8. 一方向材層における熱可塑性樹脂の存在量が、連続炭素繊維100重量部に対し、30〜200重量部である事を特徴とする補強材を使用した上記1.〜7.項のいずれかに記載の接合体。
9. 一方向材層が、連続炭素繊維を一方向に引き揃えた一方向材に熱可塑性樹脂を含浸あるいは半含浸させたものであることを特徴とする上記1.〜8.項のいずれかに記載の接合体。
ランダム層(チョップド炭素繊維および熱可塑性樹脂は、補強材のランダム層に含まれるものと同じものでも、異なるものでも良い)および一方向材層(連続炭素繊維および熱可塑性樹脂は、補強材の一方向材層に含まれるものと同じものでも、異なるものでも良い)よりなる群から選ばれる少なくとも1つを有する、開断面形状の被補強材と、
中空閉断面を作るように振動溶着された接合体であり、簡略に言うと炭素繊維強化複合材料の接合体である。
以下、本発明の接合体の実施形態について示し、本発明の接合体の一例を図1に示すが、本発明はこれらに限定されるものではない。
[補強材]
本発明の接合体に含まれる補強材は、熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム層と、連続炭素繊維が熱可塑性樹脂(ランダム層に含まれる熱可塑性樹脂と同じものでも異なるものでも良い)中に一方向にそろえて配置されている一方向材層とをそれぞれ少なくとも1層ずつ有するものであり、その具体例について図2に示す。
本発明の接合体に含まれる補強材がハット形状のものである場合、積層の形態としては、ある層の内側の全体か一部、外側の全体か一部、外側および内側それぞれの全体、外側および内側それぞれの一部、または、外側および内側のいずれか一方の一部と他方の全部などに、他の層が積層されているものも好ましい。また、“他の層”は、複数に分割された形態で積層されてもよい。具体例として、ランダム層と一方向材層のそれぞれ1層ずつからなる種々の積層形態の、ハット形状の補強材の構造例について図3に示す。言うまでも無く、図3に例示する各積層形態において、ランダム層と一方向材層を入れ替えた構造の補強材も本発明の接合体に好ましいものとして使用することができる。
また、上記補強材としては、ランダム層の全体積に対し、一方向材層が5〜100Vol%の体積にて存在するもの、言い方を変えると、ランダム層の全体積を100体積部とした場合、一方向材層の体積が5〜100体積部であるものが好ましい。
本発明の接合体に含まれる被補強材は、ランダム層(チョップド炭素繊維および熱可塑性樹脂は、補強材のランダム層に含まれるものと同じものでも、異なるものでも良い)および一方向材層(連続炭素繊維および熱可塑性樹脂は、補強材の一方向材層に含まれるものと同じものでも、異なるものでも良い)よりなる群から選ばれる少なくとも1つを有し、かつ開断面形状を有するものである。ここで「開断面形状」とは部材の断面が、箱断面のように閉じたものではない形状をいい、具体例を図1に示す。
本発明の接合体の補強材や被補強材が有するランダム層とは、熱可塑性樹脂にチョップド炭素繊維がランダム配向している層を言う。該ランダム層としては、チョップド炭素繊維が繊維長10〜100mmのものであると好ましく、更に、該チョップド炭素繊維が25〜3000g/m2の目付けにて実質的に2次元ランダムに配向しているものが好ましい。ここで、該チョップド炭素繊維が、実質的に2次元ランダムに配向しているとは、該チョップド炭素繊維が、当該ランダム層の接表面内に繊維軸の主配向方向があり、かつ、その面内において互いに直行する二方向に測定した引張弾性率の値のうち大きいものを小さいもので割った比が2を超えないものをいう。
また、該ランダム層は、本発明の効果を阻害しないものであれば、チョップド炭素繊維、熱可塑性樹脂以外の第3成分(フラーレンやカーボンナノチューブといった他の炭素材料、熱硬化性樹脂、金属、セラミック、ガラス等の異素材、各種添加剤など)を含んでいても良い。
本発明の接合体の補強材や被補強材が複数のランダム層を有する場合、そのうち上記の好ましい態様を満たすものは1層だけでも良く、複数あっても良く、全てであっても良い。
本発明の接合体の補強材や被補強材が有する一方向材層とは、連続炭素繊維が熱可塑性樹脂(ランダム層に含まれる熱可塑性樹脂と同じものでも異なるものでも良い)中に一方向にそろえて配置されているものを言い、本発明において、一方向材とは連続炭素繊維を指す。
上記一方向材層を構成する連続炭素繊維の平均繊維径は好ましくは3〜12μmであり、より好ましくは5〜7μmである。
また、上記一方向材層としては、連続炭素繊維を一方向に引き揃えた一方向材に熱可塑性樹脂を含浸あるいは半含浸させる等して、連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている連続炭素繊維強化複合材料が層状に成形されたものが好ましい。
本発明の接合体の補強材や被補強材が複数の一方向材層を有する場合、そのうち上記の好ましい態様を満たすものは1層だけでも良く、複数あっても良く、全てであっても良い。
本発明の接合体の補強材や被補強材が有するランダム層や一方向材層は熱可塑性樹脂をマトリックス(樹脂)とするものである。該熱可塑性樹脂としては、ポリアミド、ポリカーボネート、ポリオキシメチレン、ポリフェニレンスルフィド、ポリフェニレンエーテル、変性ポリフェニレンエーテル、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート、ポリエチレン、ポリプロピレン、ポリスチレン、ポリメチルメタクリレート、AS樹脂、ABS樹脂などおよびこれら2種類以上の樹脂組成物からなる群より選ばれる少なくとも1種が好ましいものとして挙げられる。特に、コストと物性の兼ね合いからポリアミド、ポリプロピレン、ポリカーボネート、ポリフェニレンスルフィド、およびこれら2種類以上の樹脂組成物からなる群より選ばれる少なくとも1種がより好ましい。
本発明において、上記熱可塑性樹脂と、前記のチョップド炭素繊維や連続炭素繊維を混合し、前記ランダム層や一方向材層を形成する方法としては公知の混練、含浸、成形技術を適用することができる。
本発明において、前記のランダム層に含まれるチョップド炭素繊維とは、炭素繊維を短くカットしたものであり、サイズ剤を用いて集束したものも含め公知のものを使用することができ、複数の種類・銘柄のものを使用しても良い。本発明において用いられるチョップド炭素繊維の好ましいものについては、ランダム層に関して前記したとおりである。
また、本発明において、被補強材がランダム層を有する場合、該ランダム層が含有するチョップド炭素繊維は、補強材のランダム層に含まれるものと同じものでも異なるものでも良い。
本発明において、前記の一方向材層に含まれる連続炭素繊維とは、チョップ、ミル、粉砕等の短繊維加工をされていない炭素繊維であり、かつウイスカ状でもない長繊維のものを指す。
本発明においては、公知の連続炭素繊維を使用することができ、複数の種類・銘柄のものを使用しても良い。 本発明において用いられる連続炭素繊維の好ましいものについては、ランダム層に関して前記したとおりである。
また、本発明において、被補強材が一方向材層を有する場合、該一方向材層が含有する連続炭素繊維は、補強材の一方向材層に含まれるものと同じものでも異なるものでも良い。
本発明の接合体を得るために用いられる、振動溶着とは2つの部材を加圧により接触させた状態で、周期的に振動させることにより2部材間に発生する摩擦熱により樹脂を溶融させて接合する方法であり、公知の振動溶着機を用いて行うことができる。
2.被補強材
3.ランダム層
4.一方向材層
Claims (7)
- 熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム層と、連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている一方向材層とをそれぞれ少なくとも1層ずつ有する補強材が、
ランダム層および一方向材層よりなる群から選ばれる少なくとも1つを有する、開断面形状の被補強材と中空閉断面を作るように振動溶着されており、
前記補強材は、前記ランダム層及び前記一方向材層の一方をコア材とし、他方をスキン層とした積層構造を有する、接合体。 - 熱可塑性樹脂にチョップド炭素繊維がランダム配向しているランダム炭素繊維強化複合材料と、連続炭素繊維が熱可塑性樹脂中に一方向にそろえて配置されている連続炭素繊維強化複合材料とを合わせて型内にてプレスすることにより、それぞれをランダム層、一方向材層とした立体形状である補強材を使用した請求項1に記載の接合体。
- ランダム層に含まれるチョップド炭素繊維が繊維長10〜100mmのものである請求項1又は2に記載の接合体。
- ランダム層の全体積に対し、一方向材層が5〜100Vol%の体積にて存在する補強材を使用した請求項1〜3のいずれか1項に記載の接合体。
- ランダム層における熱可塑性樹脂の存在量が、チョップド炭素繊維100重量部に対し、50〜1000重量部である事を特徴とする補強材を使用した請求項1〜4のいずれか1項に記載の接合体。
- 一方向材層における熱可塑性樹脂の存在量が、連続炭素繊維100重量部に対し、30〜200重量部である事を特徴とする補強材を使用した請求項1〜5のいずれか1項に記載の接合体。
- 一方向材層が、連続炭素繊維を一方向に引き揃えた一方向材に熱可塑性樹脂を含浸あるいは半含浸させたものであることを特徴とする請求項1〜6のいずれか1項に記載の接合体。
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JP6170837B2 (ja) | 2011-09-06 | 2017-08-02 | 帝人株式会社 | 繊維強化複合材料から構成される表面意匠性が優れた成形体 |
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US20130309001A1 (en) | 2013-11-21 |
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