JP5716192B2 - Forms for objects other than flying objects or windmills - Google Patents

Description

  The present invention relates to a molded article for an article other than a flying object or an article of a carbon fiber reinforced composite material using a carbon fiber as a reinforcing material and a resin composition as a matrix. The present invention relates to a molded body for high-speed moving bodies such as automobiles and vehicles that move at high speeds.

  A composite material (hereinafter referred to as CFRP) containing carbon fiber and resin is used or studied as a structural material for high-speed moving bodies such as automobiles, vehicles, and aircraft that move at high speed.

  This CFRP is often manufactured by impregnating carbon fiber with a resin to produce a semi-cured prepreg sheet, and then heat-pressing the prepreg sheet.

  Conventionally, the following has been disclosed as a technique for producing a structural material for a high-speed moving body using such CFRP.

  JP-T-2006-502046 (Patent Document 1) has a panel core, a plurality of prepreg layers that form an internal ply layer and surround the panel core, and a metal foil layer that is disposed outside the internal ply layer. An aircraft panel assembly is disclosed.

  Japanese Unexamined Patent Publication No. 2002-266173 (Patent Document 2) discloses a fiber reinforced plastic used as an aircraft structural material obtained by impregnating a carbon fiber with a resin.

  However, these fiber reinforced plastics cannot withstand the ignition phenomenon of extremely high temperatures (about 1500 ° C) during lightning strikes.

  As a conventional lightning strike countermeasure, a method of applying a lightning current using a conductor (mainly a copper plate) is used. However, with such a method, there is a risk that the aircraft itself will ignite if lightning energy is large. The reason for this is that during lightning strikes, the temperature becomes very high, and the resin constituting the CFRP at the lightning strikes swells (explodes), and the conductor melts due to crack breakage. The melted conductor is radiated to the outside and also radiated to the inside of the CFRP, causing damage to the CFRP.

  The resin contains water due to its molecular structure, and rain and condensation on the surface of the aircraft promotes the swelling of CFRP during lightning strikes. These damages were the biggest challenge for lightning protection.

  In order to prevent damage to the structural material of the aircraft due to lightning energy, the following conductive structure is employed.

  In JP-A-9-193296 (Patent Document 3) and JP-T 2006-502046 (Patent Document 1), a composite in which a thin plate of AL-Lu alloy and titanium alloy, copper or copper alloy is bonded to the CFRP surface is disclosed. The materials are listed.

  However, when a titanium alloy is used, the price of the composite material becomes very high. Moreover, titanium alloys are vulnerable to cosmic rays and are oxidized and corrode. Gamma rays and X-rays are generated near thunderclouds. Thunderclouds are said to occur about 500 times a day in the world, and when an aircraft flies in and around the thundercloud, corrosion of the titanium alloy proceeds. Therefore, an aircraft using a titanium alloy requires maintenance and replacement, resulting in high maintenance costs.

  Furthermore, a potential difference is generated between the layer made of a titanium alloy (or copper or copper alloy) bonded to the CFRP and the CFRP, and static electricity is stored inside the CFRP due to the potential difference.

  In addition, when an aircraft flies, static electricity is generated by the collision of rain, miso, snow, arare, etc. with the surface of the aircraft. Sometimes static electricity is also generated by dust, sand and volcanic ash. In this way, static electricity generated on the airframe surface is gradually accumulated in the CFRP, and the electric potential on the airframe surface rises. Furthermore, static electricity is generated on the rear surface of the structural material of the aircraft due to contact friction, vibration, and the like due to carpets and interior parts laid on the floor. This static electricity is charged (charged) in the CFRP. For some reason, this static electricity sparks and ignites with metal parts. In particular, sparks in the fuel chamber are a problem.

  Furthermore, a potential difference is generated between the layer made of the titanium alloy (or the component harness (rivet) metal fitting) and the CFRP, and static electricity is stored in the CFRP by the potential difference. Similarly, when an Al-Lu alloy is used, a potential difference is generated between the Al-Lu alloy and the CFRP, so that static electricity is stored and electric corrosion occurs. In the case of an aircraft, as described above, static electricity is generated in the titanium alloy or Al-Lu alloy bonded to the surface by volcanic ash, dust, or the like. Since all the generated static electricity is a direct current, when the current flows in the metal, the degree of corrosion is larger than the alternating current. The difference in resistance depending on the degree of corrosion causes a potential difference and causes static electricity (direct current). This also contributes to the ignition.

  Therefore, it is necessary to protect the tip of the fastener (titanium alloy rivet) with an insulating material, which increases costs (for example, Japanese Patent Laid-Open No. Sho 62-168394 (Patent Document 4), Special Table 2010-512270). Gazette (patent document 5)).

  Furthermore, as described in Japanese Patent Application Laid-Open No. 7-96579 (Patent Document 6), in order to prevent damage to the aircraft from lightning strikes, it is also proposed that a mesh-like (net-shaped) thing be placed in the inner layer of the CFRP. Has been. However, in this method, since there is no heat resistance except for the titanium alloy, the composite material is melted and the dissolved metal also has an adverse effect on the inside.

JP-T-2006-502046 JP 2002-266173 A JP-A-9-193296 JP 62-168394 A Special table 2010-512270 gazette JP 7-96579 A

  The present invention has been made to solve the above-described drawbacks, and an object of the present invention is to prevent swelling of a resin or the like constituting a molded body and destroy a structural material or the like even under a lightning strike. It is an object of the present invention to provide a molded body for an object other than a flying object or a windmill that can prevent the above-described problem.

  Another object of the present invention is to provide a molded body for an article other than a flying object or a windmill capable of energizing a lightning current during a lightning strike and guiding the current to a discharge rod.

  Still another object of the present invention is to provide a molded body for an article other than a flying object or a windmill which is not easily charged with static electricity.

  It is still another object of the present invention to provide a molded body for an article other than a flying object or a windmill that is easy and economical to maintain and replace the molded body.

  As a result of repeating earnest studies to solve the above problems, the present inventors desirably used a resin composition containing a resin and an aluminum titanate-based ceramic sintered powder. It has been found that by using a composite material obtained by impregnating fibers, a molded product that can eliminate the fear of flying against lightning can be obtained, and the present invention has been achieved.

That is, the molded object for articles | goods other than the windmill of this invention is characterized by the following.
(Item 1) In a molded article for an article other than a flying object or an article of a carbon fiber reinforced composite material using carbon fiber as a reinforcing material and using a resin composition as a matrix,
Molding in which the resin composition contains a resin and an aluminum titanate ceramic sintered powder, and the aluminum titanate ceramic sintered powder is dispersed in the resin in at least the surface layer of the molded body body.
(Item 2) The molded article according to item 1, wherein the aluminum titanate-based ceramic sintered powder is blended in an amount of 50 to 300 parts by weight with respect to 100 parts by weight of the resin.
(Item 3) The molded article according to item 1 or 2, wherein the aluminum titanate-based ceramic sintered powder has an average particle size of 0.001 to 100 µm.
(Item 4) In any one of Items 1 to 3, the aluminum titanate-based ceramics sintered powder is obtained by firing and pulverizing a molded body formed from a raw material containing titanium dioxide, alumina, and alkali feldspar. The molded body described.
(Item 5) The molded article according to any one of Items 1 to 4, wherein the resin is a thermosetting resin, a thermoplastic resin, or a mixture of a thermosetting resin and a thermoplastic resin.
(Item 6) The carbon fibers are carbon fibers arranged in one direction, and a plurality of resin-impregnated fiber layers obtained by impregnating the carbon fiber with the resin composition are laminated in the thickness direction to form the carbon. A fiber reinforced composite material is constructed,
In any one of items 1 to 5, the carbon fibers are oriented in one direction in each of the resin-impregnated fiber layers, and the carbon fibers are oriented in multiple directions as a whole of the plurality of resin-impregnated fiber layers. The molded body described.
(Item 7) The molded article according to item 6, wherein each of the resin-impregnated fiber layers has a thickness of 20 to 80 µm.
(Item 8) The molded article according to item 6 or 7, wherein a resin composition layer made of the resin composition is provided between the resin-impregnated fiber layer and the resin-impregnated fiber layer.
(Item 9) The carbon fibers are carbon fibers arranged in one direction, and a plurality of resin-impregnated fiber layers obtained by impregnating the carbon fibers with a resin are laminated in the thickness direction to form a carbon fiber reinforced composite material. Is configured,
In each of the resin-impregnated fiber layers, the carbon fibers are oriented in one direction, and as a whole of the plurality of resin-impregnated fiber layers, the carbon fibers are oriented in multiple directions,
Item 6. The molded article according to any one of Items 1 to 5, wherein a resin composition layer comprising the resin composition is provided between the resin-impregnated fiber layer and the resin-impregnated fiber layer.
(Item 10) The molded article according to any one of items 1 to 9, further comprising a core material, wherein the carbon fiber reinforced composite material is disposed on at least one surface of the core material.
(Item 11) The molded article according to item 10, wherein the core material is a carbon fiber reinforced composite material using carbon fiber as a reinforcing material and resin as a matrix.
(Item 12) The molded article according to any one of items 1 to 11, wherein a resin composition layer formed by applying the resin composition is provided on at least one surface of the carbon fiber reinforced composite material. .

  For example, it is said that the ignition heat that an aircraft molded body receives during lightning strikes is about 1,500 ° C. The resin contained in the molded body is swollen by the ignition heat at this moment, so that the molded body explodes and is destroyed.

  According to the molded body for an article other than the flying object or windmill of the present invention, the carbon fiber reinforced composite material constituting the molded body contains a resin and an aluminum titanate ceramic sintered powder, and the titanium Since the aluminum oxide-based ceramic sintered powder is dispersed in the resin of at least the surface layer of the molded body, it prevents swelling of the resin in the molded body due to sudden heat generation when the molded body receives a lightning strike. be able to. The reason is presumed as follows.

  The aluminum titanate-based ceramic sintered powder dispersed and present in the compact has a low expansion, and its linear expansion is substantially the same as that of the carbon fibers present in the compact. Moreover, the aluminum titanate ceramic sintered powder has heat resistance. Therefore, the molded body in which the aluminum titanate ceramic sintered powder is dispersed in the resin can prevent the resin portion from swelling and improve the heat resistance. Furthermore, the electrical resistance of the molded body is lowered and it becomes relatively easy to conduct. Moreover, since it has a low resistance, it is difficult to be charged. Therefore, the lightning current at the time of lightning can easily flow through the molded body, so that it can be guided to the discharge rod. Furthermore, since the ceramic sintered powder is dispersed in the resin, the charged volume of the molded body is reduced, and the molded body can be made less likely to be charged with static electricity.

  Moreover, since the surface of the aluminum titanate-based ceramics sintered powder has irregularities, it can be expected that an anchor effect with the resin can be expected and the adhesiveness is excellent.

  In particular, the molded body has a large number of layers, and an aluminum titanate ceramic sintered powder is dispersed in the surface layer, so that no potential difference is generated between the intermediate layer and the surface layer. Further, even when the surface layer is damaged by an external impact or the like, it becomes a cushion and can be stopped in the lower layer, so that a molded article having excellent impact resistance can be obtained.

  Since the molded body is not oxidized and corrosion does not proceed like the titanium alloy, the molded body can be easily maintained and replaced, and is also economical.

  Furthermore, by using the opened carbon fiber, the aluminum titanate ceramic sintered powder is more uniformly dispersed in the thickness direction. Therefore, it becomes a molded body in which the swelling of the resin portion is further prevented.

It is the schematic which shows a prepreg sheet manufacturing apparatus. It is the schematic which shows another prepreg sheet manufacturing apparatus. It is a top view which shows the simulation test apparatus of a lightning strike. It is sectional drawing which shows the simulation test apparatus of a lightning strike. This is an equivalent circuit used for a lightning simulation test device. It is a schematic explanatory drawing of a penetration test apparatus. It is explanatory drawing of an electrostatic dissipation test apparatus. It is explanatory drawing of an electrostatic voltage measurement test apparatus. It is explanatory drawing of an electrostatic capacitance measurement test apparatus. 10 is an applied waveform of a lightning impulse current test of a molded body of Example 7. FIG. 10 is an applied waveform of a lightning impulse current test of a molded article of Example 8. FIG. It is an application waveform of the lightning impulse current test of the molded article of Example 9. FIG. 13A shows an impulse waveform of a discharge voltage implemented using a lightning strike simulation test apparatus according to the present invention, and FIG. 13B shows a discharge voltage implemented using a typical lightning strike simulation test apparatus. It is an impulse waveform. It is an applied waveform in the penetration direction of Example 9. FIG. 10 is an applied waveform in the penetration direction of Example 7. FIG. It is a graph of the molded object of the comparative example 2 which shows an electrostatic dissipation test result. It is a graph of the molded object of the comparative example 2 which shows an electrostatic dissipation test result. It is a graph of the molded object of Example 4 which shows an electrostatic dissipation test result. It is a graph of the molded object of Example 5 which shows an electrostatic dissipation test result. It is a graph of the molded object of Example 6 which shows an electrostatic dissipation test result.

  Embodiments of the present invention will be described below.

  Molded articles for articles other than flying objects or windmills of the present invention include, for example, automobiles such as buses, trucks, passenger cars, and special vehicles; railway vehicles such as trains, trains, high-speed rail vehicles, and linear motor car vehicles; passenger ships It can be used for cargo ships, tankers, pleasure boats, hydrofoil ships, submarines, submersibles and other ship vessels, unmanned robots, and the like. These are used as vehicle bodies, structural materials, etc., or as a part thereof.

The molded body of the present invention is obtained by molding a carbon fiber reinforced composite material using carbon fibers as a reinforcing material and using a resin composition as a matrix.
(Molded body)
In the present invention, the molded product refers to any product obtained by molding a material containing resin and fibers. As a molding method, any method known as a molding method of a resin material can be used.

  The size of the molded body is not particularly limited. For example, a large structure such as a vehicle body may be manufactured as a single molded body, or a part thereof may be manufactured as a single molded body, and a large number of molded bodies may be combined to manufacture the structure. Good.

  The thickness of the molded body is not particularly limited. The thickness can be designed according to the performance required for the molded body. The thickness of the molded body is preferably 0.1 mm or more, more preferably 1 mm or more, and can also be 3 mm or more. Furthermore, it is preferably 50 mm or less, more preferably 30 mm or less, and may be 10 mm or less as necessary, or 5 mm or less.

  As the resin for the molded body, the resins described in relation to the prepreg sheet can be used.

  The carbon fiber described in relation to the prepreg sheet can be used as the carbon fiber for the molded body.

  As the aluminum titanate-based ceramic sintered powder for the formed body, the aluminum titanate-based ceramic sintered powder described in relation to the prepreg sheet can be used.

  The amount of the aluminum titanate ceramic sintered powder in the molded body is not particularly limited. Preferably, it is 20 parts by weight or more with respect to 100 parts by weight of the resin, more preferably 30 parts by weight or more, and if necessary, it can be 40 parts by weight or more, and 50 parts by weight or more. It is also possible to make it 60 parts by weight or more. If it is 50 parts by weight or more, very high performance such as lightning resistance can be achieved. However, when trying to achieve much more severe lightning resistance, 70 parts by weight or more and 80 parts by weight with respect to 100 parts by weight of resin. It is preferable that the amount is 90 parts by weight or more. Furthermore, it is preferably 300 parts by weight or less, more preferably 200 parts by weight or less, still more preferably 150 parts by weight or less, still more preferably 120 parts by weight or less, with respect to 100 parts by weight of the resin. Preferably, it is 100 parts by weight or less, and if necessary, it can be 80 parts by weight or less, can be 50 parts by weight or less, and can be 40 parts by weight or less. It may be 30 parts by weight or less. If the amount is too small, it may be difficult to obtain appropriate lightning resistance and static electricity resistance of the molded body. If the amount is too large, the weight of the molded body may be too heavy.

The content of the carbon fiber in the molded body is not particularly limited, but is preferably 10% or more, more preferably 20% or more, and 30% or more as necessary, as the fiber volume%. Yes, it may be 40% or more. Further, the fiber volume% in the molded body is preferably 80% or less, more preferably 70% or less, and may be 60% or less as necessary. If the amount of carbon fiber is too small, the strength of the molded body tends to decrease. If the amount of carbon fiber is too large, it may be difficult to impregnate the resin, and voids may be formed.
(Layer structure)
The molded body of the present invention preferably has a core material and a surface layer, and more preferably has a first surface layer, a core material and a second surface layer. Here, a 1st surface layer is a part which contacts external air of this molded object, Comprising: It is a part which a lightning may contact first, and a 2nd surface layer is opposite to a 1st surface layer The core material is a portion sandwiched between the first surface layer and the second surface layer. For example, in the case of a vehicle body, the portion in contact with the outside air outside is the first surface layer, and the surface on the cabin side is the second surface layer.

  If necessary, a configuration without a core material may be used. That is, a molded object may be comprised only from a 1st surface layer and a 2nd surface layer.

In the present invention, the presence of the aluminum titanate-based ceramic sintered powder in both the first surface layer and the second surface layer improves the lightning resistance and static electricity resistance of the molded body to a high degree. When there is no aluminum titanate-based ceramic sintered powder in either the first surface layer or the second surface layer, the lightning resistance and electrostatic resistance of the molded body are significantly reduced.
(First surface layer)
The first surface layer contains a resin, an aluminum titanate ceramic sintered powder, and carbon fibers.

  As the material for the first surface layer, the same materials as those described for the prepreg sheet can be used.

  The thickness of the first surface layer is not particularly limited. Preferably it is 0.01 mm or more, More preferably, it is 0.05 mm or more. If necessary, it can be 0.1 mm or more, and can be 0.3 mm or more. It is also possible to make it above, and it is also possible to set it as 1 mm or more, and it is also possible to set it as 3 mm or more. Furthermore, it is preferably 50 mm or less, more preferably 30 mm or less, and if necessary, it can be 20 mm or less, can be 10 mm or less, and can be 5 mm or less. 3 mm or less is also possible, and 1 mm or less is also possible. If the thickness is too thin, it may be difficult to obtain appropriate lightning resistance and electrostatic resistance of the molded body. When the thickness is too thick, the weight of the molded body may be too heavy.

  The amount of the aluminum titanate ceramic sintered powder in the first surface layer is not particularly limited. Preferably, it is 20 parts by weight or more with respect to 100 parts by weight of the resin, more preferably 30 parts by weight or more, and if necessary, it can be 40 parts by weight or more, and 50 parts by weight or more. It is also possible to make it 60 parts by weight or more. Furthermore, it is preferably 300 parts by weight or less with respect to 100 parts by weight of the resin, more preferably 200 parts by weight or less, and if necessary, it can be 150 parts by weight or less, and 100 parts by weight or less. It is also possible to make it 80 parts by weight or less, and it is also possible to make it 50 parts by weight or less. If the amount is too small, it may be difficult to obtain appropriate lightning resistance and static electricity resistance of the molded body. If the amount is too large, the weight of the molded body may be too heavy.

  The content of the carbon fiber in the first surface layer is not particularly limited, but is preferably 10% or more, more preferably 20% or more, and more preferably 30% or more as fiber volume%. It is also possible to make it 40% or more. Further, the fiber volume% in the first surface layer is preferably 80% or less, more preferably 70% or less, and may be 60% or less as necessary. If the amount of carbon fiber is too small, the strength of the molded body tends to decrease. If the amount of carbon fiber is too large, it may be difficult to impregnate the resin.

The 1st surface layer can contain materials other than resin, aluminum titanate ceramic sintered powder, and carbon fiber as needed. It is preferable not to include materials other than resin, aluminum titanate ceramic sintered powder and carbon fiber. Examples of materials other than resin, aluminum titanate ceramic sintered powder, and carbon fiber include materials used for conventional resin materials (for example, carbon fiber reinforced plastic) (for example, colorants, fillers, and the like). Can be used. When materials other than resin, aluminum titanate ceramic sintered powder and carbon fiber are used, the amount is not particularly limited, but a small amount is preferable to achieve high lightning resistance and electrostatic resistance. . For example, it is preferably 50 parts by weight or less, more preferably 30 parts by weight or less, 20 parts by weight or less, 10 parts by weight or less, 5 parts by weight or less, 3 parts by weight or less with respect to 100 parts by weight of the resin. More preferably, it is 1 part by weight or less or 0.1 part by weight or less. Further, it can be 0.01 parts by weight or more with respect to 100 parts by weight of the resin, and can also be 0.05 parts by weight or more. If the amount is too small, it may be difficult to obtain the effect of using the material.
(Second surface layer)
The second surface layer contains a resin, an aluminum titanate ceramic sintered powder, and carbon fibers.

  As the material for the second surface layer, the same materials as those described for the prepreg sheet can be used.

  The thickness of the second surface layer is not particularly limited. Preferably it is 0.01 mm or more, More preferably, it is 0.05 mm or more. If necessary, it can be 0.1 mm or more, and can be 0.3 mm or more. It is also possible to make it above, and it is also possible to set it as 1 mm or more, and it is also possible to set it as 3 mm or more. Furthermore, it is preferably 50 mm or less, more preferably 30 mm or less, and if necessary, it can be 20 mm or less, can be 10 mm or less, and can be 5 mm or less. 3 mm or less is also possible, and 1 mm or less is also possible. If the thickness is too thin, it may be difficult to obtain appropriate lightning resistance and electrostatic resistance of the molded body. When the thickness is too thick, the weight of the molded body may be too heavy.

  The amount of the aluminum titanate ceramic sintered powder in the second surface layer is not particularly limited. Preferably, it is 20 parts by weight or more with respect to 100 parts by weight of the resin, more preferably 30 parts by weight or more, and if necessary, it can be 40 parts by weight or more, and 50 parts by weight or more. It is also possible to make it 60 parts by weight or more. Furthermore, it is preferably 300 parts by weight or less with respect to 100 parts by weight of the resin, more preferably 200 parts by weight or less, and if necessary, it can be 150 parts by weight or less, and 100 parts by weight or less. It is also possible to make it 80 parts by weight or less, and it is also possible to make it 50 parts by weight or less. If the amount is too small, it may be difficult to obtain appropriate lightning resistance and static electricity resistance of the molded body. If the amount is too large, the weight of the molded body may be too heavy.

  The content of the carbon fiber in the second surface layer is not particularly limited, but is preferably 10% or more, more preferably 20% or more, and 30% or more as necessary, as the fiber volume%. It is also possible to make it 40% or more. Further, the fiber volume% in the second surface layer is preferably 80% or less, more preferably 70% or less, and may be 60% or less as necessary. If the amount of carbon fiber is too small, the strength of the molded body tends to decrease. If the amount of carbon fiber is too large, it may be difficult to impregnate the resin.

The 2nd surface layer can contain materials other than resin, aluminum titanate ceramic sintered powder, and carbon fiber as needed. It is preferable not to include materials other than resin, aluminum titanate ceramic sintered powder and carbon fiber. Examples of materials other than resin, aluminum titanate ceramic sintered powder, and carbon fiber include materials used for conventional resin materials (for example, carbon fiber reinforced plastic) (for example, colorants, fillers, and the like). Can be used. When materials other than resin, aluminum titanate ceramic sintered powder and carbon fiber are used, the amount is not particularly limited, but a small amount is preferable to achieve high lightning resistance and electrostatic resistance. . For example, it is preferably 50 parts by weight or less, more preferably 30 parts by weight or less, 20 parts by weight or less, 10 parts by weight or less, 5 parts by weight or less, 3 parts by weight or less with respect to 100 parts by weight of the resin. More preferably, it is 1 part by weight or less or 0.1 part by weight or less. Further, it can be 0.01 parts by weight or more with respect to 100 parts by weight of the resin, and can also be 0.05 parts by weight or more. If the amount is too small, it may be difficult to obtain the effect of using the material.
(Core material)
The material which comprises a core material is not specifically limited. It can be made of any material. It may be an inorganic material or an organic material. In a preferred embodiment, the material includes a resin. More preferably, it is a material containing resin and fiber.

When a resin is used for the core material, the resin may be a thermosetting resin or a thermoplastic resin. Any of the resins described for the molded body and the prepreg sheet of the present invention can be used for the core material. In one preferred embodiment, the core material is made of carbon fiber reinforced plastic.
Moreover, wood (such as a balsa material), a honeycomb structure, or the like can also be used as the core material. Examples of the honeycomb structure include a Nomex honeycomb made of an aramid fiber and a phenol resin, and one made of a non-ferrous metal (Al or Al-Lu). Thus, CFRP (containing ceramics) can be combined and strengthened by using a core material such as wood (such as a balsa material). Aircraft structural materials have a certain standard, and a core material that can satisfy standards such as strength, rigidity (tensile strength), elasticity, and toughness is required. For example, a core material (for example, a flooring material for a civil transport aircraft) used for a military transport aircraft, a civil transport aircraft, or the like can be used. Therefore, a sandwich structure or a two-layer structure of a core material and CFRP (containing ceramics) can also be used.

  The core material may be composed of a plurality of layers. In this specification, the whole part which exists between a 1st surface layer and a 2nd surface layer is called a core material for convenience. The core material may include a layer made of the same material as the first surface layer or the second surface layer. For example, when the molded body is composed of five layers and the layers A and B are laminated in the order of “layer A / layer B / layer A / layer B / layer A”, the middle three layers are the core material. Become.

  The thickness of the core material is not particularly limited. For example, the thickness of the core can be obtained by subtracting the thickness of the first surface layer and the thickness of the second surface layer from the desired thickness of the molded body.

  When the core material is a resin material, the core material may or may not contain aluminum titanate ceramic sintered powder. When the core material contains aluminum titanate ceramic sintered powder, the amount is not particularly limited. Preferably, it is 20 parts by weight or more with respect to 100 parts by weight of the resin, more preferably 30 parts by weight or more, and if necessary, it can be 40 parts by weight or more, and 50 parts by weight or more. It is also possible to make it 60 parts by weight or more. Furthermore, it is preferably 300 parts by weight or less with respect to 100 parts by weight of the resin, more preferably 200 parts by weight or less, and if necessary, it can be 150 parts by weight or less, and 100 parts by weight or less. It is also possible to make it 80 parts by weight or less, and it is also possible to make it 50 parts by weight or less. If the amount is too small, it may be difficult to obtain appropriate lightning resistance and static electricity resistance of the molded body. If the amount is too large, the weight of the molded body may be too heavy.

  When the core material is a resin material, the core material may or may not contain carbon fibers. When the core material contains carbon fiber, the amount is not particularly limited, but is preferably 10% or more, more preferably 20% or more, and more preferably 30% or more, or as fiber volume%. It is also possible to make it 40% or more. Further, the fiber volume% in the molded body is preferably 80% or less, more preferably 70% or less, and may be 60% or less as necessary. If the amount of carbon fiber is too small, the strength of the molded body tends to decrease. If the amount of carbon fiber is too large, it may be difficult to impregnate the resin.

  The molded article of the present invention typically uses a carbon fiber as a reinforcing material and a carbon fiber reinforced composite material using a resin composition as a matrix in a molding apparatus such as an autoclave apparatus, and is heated and pressurized. It is created by curing the resin of the resin composition.

  The carbon fiber reinforced composite material may be a prepreg laminated material constituted by laminating a plurality of prepreg sheets, and has various forms shown below. The resin composition as one component of the carbon fiber reinforced composite material contains at least a resin and an aluminum titanate ceramic sintered powder.

  The carbon fiber reinforced composite material can form the first surface layer, the second surface layer, and / or the core material described above.

(Painting)
If necessary, the molded body described above may be coated on the surface after the molding step. Further, the surface after the molding step obtained without painting may be used as the surface of the final product as it is. When painting, it is preferable to use a paint containing an aluminum titanate ceramic sintered powder from the viewpoint of lightning resistance and the like.
(Form of carbon fiber reinforced composite material)
The carbon fiber reinforced composite material used in the present invention includes, for example, the following forms.
(1) A carbon fiber reinforced composite material comprising a prepreg sheet in which a carbon fiber is impregnated with a resin composition.

  The composite material may be a single prepreg sheet or a prepreg sheet in which a plurality of layers are laminated.

  When the composite material is a laminate of a plurality of prepreg sheets, the resin composition contained in at least one prepreg sheet contains an aluminum titanate ceramic sintered powder. The aluminum titanate-based ceramic sintered powder may be dispersed substantially uniformly in the resin, or may be present in a state of being distributed in a large amount on the surface side of the prepreg sheet.

Moreover, when the carbon fiber reinforced composite material is a laminated material constituted by laminating a plurality of prepreg sheets, the plurality of prepreg sheets may be the same or different prepreg sheets. In addition, the prepreg sheets may be laminated so that the fiber directions are in the same direction, or may be laminated in different directions. That is, the carbon fiber is a carbon fiber aligned in one direction, and a plurality of resin-impregnated fiber layers obtained by impregnating the carbon fiber with the resin composition are laminated in the thickness direction to form the carbon fiber reinforced composite. It is preferable that the material is constituted, the carbon fibers are oriented in one direction in each of the resin-impregnated fiber layers, and the carbon fibers are oriented in multiple directions as a whole of the plurality of resin-impregnated fiber layers. In the present invention, a laminate of a plurality of prepreg sheets is referred to as a prepreg laminate.
(2) A carbon fiber reinforced composite material comprising a core and a prepreg or prepreg laminate laminated on at least one surface of the core.

  The first and second surface layers of the molded body can be formed from a prepreg laminate of carbon fiber reinforced composite material.

  The core material may be a prepreg sheet or prepreg laminate formed by impregnating carbon fiber with a resin composition containing aluminum titanate ceramic sintered powder, or aluminum titanate ceramic sintered It may be a prepreg sheet or a prepreg laminate formed by impregnating carbon fiber with a resin composition not containing powder, or a structure such as a resin plate, a bartam plate, a general CFRP, a body constituting a moving body, etc. It may be a material.

  As the resin plate, a thermoplastic resin plate such as polycarbonate or polyester or a thermosetting resin plate can be used.

  When laminating the prepreg laminate, it is preferable to arrange the prepreg laminate containing the aluminum titanate ceramic sintered powder on the surface side.

It is preferable that a layer made of a prepreg laminate is formed on the surface layer and the back surface layer of the molded body.
(3) A carbon fiber reinforced composite material formed by laminating a plurality of the prepreg laminates.

  As described above, the prepreg laminate is formed by impregnating a carbon fiber with a resin composition containing an aluminum titanate-based ceramics sintered powder to form a prepreg sheet, and laminating the prepreg sheets in multiple layers. It is.

The structure of each prepreg laminated material to be laminated may be the same or different. That is, in the prepreg laminated material, the blending ratio of the resin to be used, the aluminum titanate ceramic sintered powder, the particle diameter, the carbon fiber, the number, basis weight, orientation, etc. can be arbitrarily changed according to the purpose. it can.
(4) Carbon fiber reinforced having a prepreg sheet and a resin layer comprising a resin and a resin composition containing an aluminum titanate ceramic sintered powder provided on the surface (one side or both sides) of the prepreg sheet Composite material.

  As described later, the prepreg sheet can be a prepreg sheet formed by impregnating carbon fiber with a resin composition containing a resin and an aluminum titanate-based ceramic sintered powder, or titanic acid. A conventionally known prepreg sheet containing no aluminum-based ceramic sintered powder can also be used.

  In order to provide the resin layer on the surface of the prepreg, a known method can be employed. For example, the resin layer may be provided by applying a resin composition to the surface of the prepreg.

The resin composition used for the resin layer may be the same as or different from the resin composition used for the prepreg sheet.
(5) Carbon having a prepreg laminated material and a resin layer made of a resin composition containing a resin and an aluminum titanate-based ceramic sintered powder provided on the surface (one side or both sides) of the prepreg laminated material Fiber reinforced composite material.

  As the prepreg laminate, a prepreg laminate formed by impregnating carbon fiber with a resin composition containing a resin and an aluminum titanate ceramic sintered powder can be used, or an aluminum titanate ceramic A prepreg laminate using a conventionally known prepreg sheet that does not contain sintered powder can also be used.

  In order to provide the resin layer on the surface of the prepreg laminate, a known method can be employed. For example, the resin layer may be provided by applying a resin composition to the surface of the prepreg laminate.

The resin composition used for the resin layer may be the same as or different from the resin composition used for the prepreg sheet.
(6) In the carbon fiber reinforced composite material of the above (4) and (5), an aluminum titanate ceramic is used instead of the resin layer comprising a resin composition containing a resin and an aluminum titanate ceramic sintered powder. Carbon fiber reinforced composite material provided with a layer of sintered powder.

The layer made of this aluminum titanate-based ceramic sintered powder can be provided on the front surface and / or the back surface of the prepreg sheet or prepreg laminate without using a resin, either directly or using an inorganic material.
(7) Further, as the reinforcing fibers for reinforcing the prepreg sheet, there are those made into a cloth shape such as a woven fabric, a knitted fabric, a braided fabric and a non-woven fabric. These reinforcing fibers are directly combined with a resin, or a filament is used. A semi-finished product called a prepreg is manufactured by impregnating synthetic resin into regularly arranged sheets or fabrics, etc., and an appropriate number of these prepregs are overlaid as necessary to complete the final product with an autoclave or other device. And the like.

In addition, you may create a prepreg sheet | seat using the carbon fiber which spreads carbon fiber or does not open in advance.
(Prepreg sheet)
The prepreg sheet is formed by impregnating carbon fibers with a resin composition containing a resin and an aluminum titanate ceramic sintered powder (hereinafter also simply referred to as ceramics).

  Ceramics may be uniformly dispersed in the resin, or may be unevenly distributed in the resin. Depending on the particle diameter of the ceramic used, the thickness of the carbon fiber used, the basis weight, etc., the ceramic may be dispersed on the surface of the prepreg sheet.

Depending on the manufacturing method of the prepreg sheet, the dispersion state of the ceramics may change. For example, a resin composition may be prepared by uniformly dispersing and mixing ceramics in advance in a resin, and a prepreg sheet may be prepared by impregnating the resin composition into carbon fibers, or a resin that does not contain ceramics may be added to carbon fibers. After impregnating, ceramics may be dispersed on the surface of the carbon fiber by a method such as spraying. Furthermore, you may make it produce a prepreg sheet | seat by apply | coating the resin composition containing ceramics on the surface of carbon fiber. In this invention, it is not limited to the manufacturing method of a prepreg sheet, The prepreg sheet manufactured by any method shall be included in this invention.
(Resin composition)
The resin composition contains a resin and an aluminum titanate ceramic sintered powder.

  The content ratio of the resin and the ceramic is 20 parts by weight or more with respect to 100 parts by weight of the resin, more preferably 30 parts by weight or more, and if necessary, can be 40 parts by weight or more. It can be 50 parts by weight or more, and can be 60 parts by weight or more. Furthermore, it is preferably 300 parts by weight or less with respect to 100 parts by weight of the resin, more preferably 200 parts by weight or less, and if necessary, it can be 150 parts by weight or less. It is also possible to make it 80 parts by weight or less, and it is also possible to make it 50 parts by weight or less.

  If the ceramic content is too small relative to the resin composition, when the molded body is subjected to a lightning strike, the effect of preventing swelling of the resin in the molded body due to sudden heat generation is small, and antistatic When the effect is lowered and the amount is too large, the moldability tends to be lowered, and the weight of the molded body is increased.

  There is no restriction | limiting in particular in the kind of resin used for this invention, Either a thermosetting resin or a thermoplastic resin can be used. In a preferred embodiment, it is a thermosetting resin or a mixture of a thermosetting resin and a thermoplastic resin.

  As the thermosetting resin, epoxy resin, phenol resin, bismaleimide resin, triazine resin, BT resin, unsaturated polyester resin, vinyl ester resin, or the like can be used.

  The epoxy resin is preferably at least one of bisphenol A (BPA) diglycidyl ether and bisphenol F (BPF) diglycidyl ether and derivatives thereof; tetraglycidyl derivative of 4,4′-diaminodiphenylmethane (TGDDM); aminophenol As well as other glycidyl ethers and glycidyl amines well known in the art.

  Examples of the thermoplastic resin include the following.

  Polyethersulfone (PES), polyphenylsulfone, polysulfone, polyester, polymerizable macrocycle (eg, cyclic butylene terephthalate), liquid crystal polymer, polyimide, polyetherimide, aramid, polyamide, polyester, polyketone, polyetheretherketone ( PEEK), polyurethane, polyurea, polyaryl ether, polyaryl sulfide, polycarbonate, polyphenylene oxide (PPO) and modified PPO, or any combination thereof.

  The above resins can be used alone or in combination. The resin may be completely impregnated into the carbon fiber or partially impregnated.

  The resin composition used in the present invention can contain at least one curing agent and curing accelerator when the resin is a thermosetting resin.

  Suitable curing agents include dicyandiamide, anhydrides, especially polycarboxylic anhydrides, such as nadic anhydride (NA), methyl nadic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, Examples include methyltetrahydrophthalic anhydride, methylhexahydrophthalic anhydride, endomethylenetetrahydrophthalic anhydride, or trimellitic anhydride.

  Other suitable curing agents include amines including aromatic amines such as 1,3-diaminobenzene, 1,4-diaminobenzene, 4,4′-diaminodiphenylmethane, and 4,4′-diaminodiphenyl sulfone ( There are polyaminosulfones such as 4,4′-DDS) and 3,3′-diaminodiphenylsulfone (3,3′-DDS). Various commercially available curing agents can be used. Preferred commercially available curing agents include dicyandiamide jER cure, DICY15 (manufactured by JER Co., Ltd.), 4,4′-diaminodiphenylsulfone (4,4′-DDS) and 3,3′-diaminodiphenylsulfone (3,3). 3'-DDS).

  When a curing agent is present, it can be present in the range of 10% to 1% by weight of the resin composition. More preferably, the curing agent can be present in the range of 8 wt% to 2 wt%. Particularly preferably, the curing agent can be present in the range of 6% to 3% by weight. Two or more curing agents can be used in combination.

  The resin composition used in the present invention can also contain a curing accelerator.

  Suitable curing accelerators include 3- (3,4-dichlorophenyl) -1,1-dimethylurea, N, N-dimethyl-N′-3,4-dichlorophenylurea (diuron), N, N-dimethyl- N'-3-chlorophenylurea (monuron), and preferably N, N- (4-methyl-m-phenylenebis [N ', N'-dimethylurea] (TDI uron). If present, it can be present in the range of 1% to 5% by weight of the resin composition.

The resin composition may further contain components such as a performance enhancer or a modifier. Examples of performance enhancers or modifiers include flexibility imparting agents, reinforcing agents / particles, additional accelerators, core-shell rubbers, flame retardants, wetting agents, pigments / dyes, flame retardants, plasticizers, UV absorbers, It can be selected from antibacterial compounds, fillers, viscosity modifiers / flow control agents, tackifiers, stabilizers, water repellents, and polymerization inhibitors.
(Aluminum titanate ceramic sintered powder)
The aluminum titanate-based ceramic sintered powder used in the present invention can include a sintered powder of an aluminum titanate ceramic and a sintered powder of a ceramic of an aluminum titanate and an additive such as alkali feldspar. The content ratio of titanium and aluminum in the aluminum titanate ceramic sintered powder is preferably 80% by weight or more, more preferably 85% by weight or more, most preferably 87% by weight or more based on the oxide of titanium and aluminum. And can be 90% by weight or more as required.

  The average particle size of the aluminum titanate ceramic sintered powder is preferably 0.001 to 100 μm, more preferably 0.001 to 30 μm, and most preferably 0.001 to 20 μm. When the average particle size of the ceramic sintered powder is too larger than 100 μm, the dispersibility of the ceramic is lowered, and the effects such as lightning prevention effect and antistatic effect may not be exhibited.

  The general characteristics of the aluminum titanate ceramics used in the present invention are as follows.

Super heat resistance: Maximum melting temperature about 2000 ℃
Ultra-low expansion: linear expansion coefficient at −40 ° C. to + 1350 ° C. is −0.3 × 10 ⁻⁶ / K to −1 × 10 ⁻⁶ / K
As the aluminum titanate ceramic sintered powder, an aluminum titanate ceramic sintered powder obtained according to the method described in Japanese Patent No. 3600933 can be used.

Specifically, alumina is used as a main raw material, and a clinker of sintered powder is obtained by adding additives such as titanium oxide, alkali feldspar, spinel (MgAl ₂ O ₄ ), and the obtained sintered powder The clinker was pulverized with a ball mill and classified with a sieve.

In addition to alkali feldspar and spinel (MgAl ₂ O ₄ ), there are iron oxide, zirconia, zircon, yttria, magnesium, strontium, SiC, β-spodumene and the like. Commercially available products include readily sintered alumina AES-11 (Sumitomo Chemical Co., Ltd.) for alumina, A-110 (manufactured by Sakai Chemical Co., Ltd.) for titanium oxide, and Fukushima feldspar for alkali feldspar.

  The aluminum titanate ceramic sintered powder can be manufactured as described above.

  When a raw material powder made of titanium dioxide and alumina is sintered to obtain an aluminum titanate ceramic sintered powder, it is obtained by allowing alkali feldspar to be present in the raw material powder. According to this manufacturing method, Si atoms contained in the alkali feldspar are dissolved in the aluminum titanate crystal, and the growth of crystal grains is suppressed, so that a dense sintered powder is obtained. The obtained sintered powder has both mechanical strength and low expansion coefficient, and is excellent in fire resistance and the like.

Specifically, a mixture containing TiO ₂ and Al ₂ O ₃ added with an alkali feldspar represented by the chemical formula: (Na _x K _1-x ) AlSi ₃ O ₈ (0 ≦ x ≦ 1) is used as a raw material. The formed body is fired at 1400 to 1700 ° C.

TiO ₂ and Al ₂ O ₃ used as raw materials are not particularly limited as long as they are components capable of synthesizing aluminum titanate by firing, and are usually various types such as alumina ceramics, titania ceramics, aluminum titanate ceramic sintered powders, and the like. What is necessary is just to select suitably from what is used as a raw material of ceramics. In particular, using the anatase-type or rutile-type TiO ₂ as TiO _2, in the case of using the sinterability alumina α-type as Al ₂ O _3, the reaction of both components is good, titanium at a high yield in a short time Aluminum oxide can be formed.

The mixing ratio of TiO ₂ and Al ₂ O ₃ may be in the range of TiO ₂ : Al ₂ O ₃ (weight ratio) = 40: 60 to 60:40, and TiO ₂ : Al ₂ O ₃ (weight ratio). = It is preferable to set it as the range of about 40: 60-45: 55.

The alkali feldspar used as an additive is represented by the chemical formula: (Na _x K _1-x ) AlSi ₃ O ₈ . In the formula, x is 0 ≦ x ≦ 1. In particular, in the above chemical formula, a range of 0.1 ≦ x ≦ 1 is preferable, and a range of 0.15 ≦ x ≦ 0.85 is more preferable. An alkali feldspar having an x value in such a range has a low melting point and is particularly effective for promoting the sintering of aluminum titanate.

The amount of alkali feldspar used is preferably about 1 to 15 parts by weight, and more preferably about 4 to 10 parts by weight with respect to 100 parts by weight of the total amount of TiO ₂ and Al ₂ O ₃ . Most preferably, it is 4 to 5 parts by weight.

If necessary, inorganic oxide materials other than alkali feldspar can be used as an additive. Examples of the inorganic oxide material include SiO ₂ , iron oxide, magnesium oxide, and aluminum oxide. When an inorganic oxide material other than alkali feldspar is used as an additive, the amount of the additive comprising the inorganic oxide material is inorganic with respect to 100 parts by weight of the total amount of TiO ₂ and Al ₂ O _3. The total amount of the additive made of an oxide-based material is preferably about 1 to 15 parts by weight, and more preferably about 4 to 10 parts by weight. Most preferably, it is 4 to 5 parts by weight.

According to this method, the above-mentioned specific alkali feldspar is added as an additive to a mixture containing TiO ₂ and Al ₂ O _3, and the mixture is formed into a predetermined shape and fired, whereby aluminum titanate Grain growth is suppressed and a dense sintered powder can be obtained. The reason for this is that when aluminum titanate is formed by firing, Si in the alkali feldspar dissolves in the crystal lattice and substitutes for Al, and since Si has a smaller ionic radius than Al, it is in contact with surrounding oxygen atoms. It is considered that the bond distance is shortened, and as a result, the crystal is densified.

The raw material mixture containing TiO ₂ , Al ₂ O ₃ and alkali feldspar is thoroughly mixed and, after firing, pulverized to an appropriate particle size.

  The mixing and pulverizing method of the raw material mixture is not particularly limited, and may be performed according to a conventional method. For example, the mixing and pulverizing may be performed using a ball mill, a medium stirring mill, or the like. Although there is no particular limitation on the degree of pulverization of the raw material mixture, it may be usually pulverized to about 100 μm or less. If necessary, the raw material mixture may further contain a molding aid. As the molding assistant, conventionally known components may be used depending on the molding method. Such molding aids include, for example, binders such as polyvinyl alcohol, micro wax emulsion, carboxymethyl cellulose, mold release agents such as stearic acid emulsion, antifoaming agents such as n-octyl alcohol, octylphenoxyethanol, diethylamine, triethylamine, and the like. A peptizer or the like can be used.

The amount of these molding aids to be used is not particularly limited, and may be appropriately selected from the same blending amount range as in the past depending on the molding method. For example, as a molding aid for casting molding, the binder is about 0.4 to 0.6 parts by weight and the peptizer 0.5 to 1 with respect to 100 parts by weight of the total amount of TiO ₂ and Al ₂ O _3. About 0.5 parts by weight, about 0.2 to 0.7 parts by weight of release agent (solid content), and about 0.03 to 0.1 parts by weight of antifoaming agent can be used.

  There are no particular limitations on the molding method of the raw material mixture, and for example, a known molding method such as press molding, sheet molding, cast molding, extrusion molding, injection molding, CIP molding, or HIP molding may be appropriately employed.

  The firing temperature may be about 1300 to 1700 ° C, preferably about 1450 to 1650 ° C. There is no particular limitation on the firing atmosphere, and any of an oxygen-containing atmosphere such as air, a reducing atmosphere, and an inert atmosphere that are usually employed may be used. In particular, when firing in a reducing atmosphere such as a carbon monoxide atmosphere, a natural gas atmosphere, or an LPG atmosphere, it is advantageous in that a dense and high-strength sintered powder is easily formed. There is no particular limitation on the firing time, and it is usually sufficient to maintain the temperature within the above-mentioned temperature range for about 1 to 10 hours.

  The sintered powder obtained by this method is an aluminum titanate-based sintered powder in which Si is dissolved in an aluminum titanate crystal lattice and substituted with Al. The lattice constant is compared with that of pure aluminum titanate. Have a small value. As a result, the obtained sintered powder has a stabilized crystal structure and becomes a sintered powder having fine crystal grains. Such a sintered powder in which the growth of crystal grains is suppressed does not cause cracks to alleviate strain due to thermal expansion, and has a dense and high mechanical strength.

  The obtained sintered powder has such excellent characteristics, has both high mechanical strength and low thermal expansion coefficient, and has a high fire resistance due to the stabilized crystal structure. Become. As a result, the decomposition reaction of aluminum titanate is suppressed and can be used stably even at a high temperature of several hundred degrees to 1600 ° C., and SK40 (1920 ° C.) is much higher than the melting point of aluminum titanate, 1860 ° C. ) It has the above fire resistance and heat resistance.

The aluminum titanate ceramic sintered powder thus obtained was used in the present invention.
(Carbon fiber)
The kind of carbon fiber is not particularly limited. Pitch-based carbon fiber or PAN-based carbon fiber is preferable. Further, the carbon fiber may be subjected to surface treatment or may not be subjected to surface treatment. The length of the carbon fiber is not particularly limited. So-called long fibers are preferred. However, so-called short fibers may be used. In the present invention, carbon fiber woven fabrics, knitted fabrics, braids and the like can also be used.
(Manufacturing method and manufacturing apparatus of prepreg sheet)
A method for producing a prepreg sheet is prepared by dispersing an aluminum titanate ceramic sintered powder in the above resin to prepare a resin composition and impregnating the carbon fiber with the resin composition to form a sheet-like resin-impregnated fiber layer. Forming the step.

  A ceramic layer in which more aluminum titanate ceramics are present than the inside may be formed on the surface side of the resin-impregnated fiber layer, or aluminum titanate-based ceramics may be present almost uniformly throughout the resin-impregnated fiber layer. Good.

  Furthermore, a resin composition layer in which an aluminum titanate-based ceramic sintered powder is dispersed in a resin is applied to the surface of a main body of a prepreg sheet obtained by impregnating carbon fiber with a normal resin, and a resin composition layer is formed by a method such as adhesion It may be formed.

  In order to disperse the aluminum titanate-based ceramic sintered powder in the resin between the carbon fibers, it is preferable that the sintered powder has a smaller particle diameter, and more preferably a powder smaller than the carbon fiber diameter is used. . When impregnating a carbon fiber bundle with a resin composition in which such a powder is dispersed in a resin, the carbon fiber and the resin composition are passed between a pair of heat and pressure rolls as a method. In general, a method of impregnating a resin composition into a carbon fiber bundle is performed, but the aluminum titanate-based ceramics sintered in the resin between carbon fibers by appropriately setting heating conditions and pressure conditions. The powder can be dispersed.

  In addition, there is a method in which the carbon fiber bundle is widened by opening or the like to ensure a wide distance between the carbon fibers in advance so that the sintered powder is easily mixed into the carbon fiber bundle.

  As a method for causing a large amount of aluminum titanate ceramic sintered powder to be present on the surface side of the resin-impregnated fiber layer, there is a method using a sintered powder having a particle size preferably larger than the carbon fiber diameter. A resin composition in which such a powder is dispersed in a resin is passed between a pair of heating and pressing rolls together with a carbon fiber bundle, and the resin and particle size of the resin composition are adjusted under appropriate heating and pressing conditions. There is a method in which fine sintered powder is impregnated in a carbon fiber bundle, and a large amount of the sintered powder having a large particle size is dispersed in the surface layer.

  As a method of attaching the resin composition to the carbon fiber bundle, when passing the carbon fiber and the resin composition between a pair of heat and pressure rolls, the heating temperature at which the resin is impregnated in the carbon fiber bundle, lower than the pressure. By setting the conditions to low pressure, or low temperature or low pressure, the carbon fiber bundle is not impregnated with the resin, and the carbon fiber can be attached to the resin.

  Here, adhesion means a state in which the carbon fiber itself is present on the surface in a state in which the carbon fiber is adhered to the resin, or a state in which the resin is slightly impregnated in the carbon fiber bundle.

  In the present invention, a prepreg sheet can be manufactured using a prepreg sheet manufacturing apparatus according to FIG. 12 of JP-T-2007-518890.

  When this production apparatus is used, a prepreg sheet is produced by impregnating a continuous carbon fiber that has been spread with a resin and drawing it in one direction to form a sheet.

  The prepreg sheet manufacturing apparatus will be described as follows.

  As shown in FIG. 1, the prepreg sheet manufacturing apparatus includes a fiber-spreading device 8 disposed between a yarn supplying unit 4 that supplies a continuous carbon fiber bundle 2 and a winding unit 6, a resin impregnated unit 10, It has.

  The fiber opening device 8 includes a fiber opening unit 12 that opens air by applying air to the carbon fiber bundle 2, a longitudinal vibration applying unit 13 that applies longitudinal vibration to the carbon fiber, and a lateral vibration application that applies lateral vibration to the carbon fiber. Part 14.

  The resin impregnation unit 10 includes a heating and pressing roll set 16 in which heating and pressing rolls are combined vertically and a cooling and pressing roll set 18 in which cooling and pressing rolls are combined in upper and lower directions. And it is comprised so that resin may be continuously impregnated on the single side | surface of the sheet-like carbon fiber 3 (henceforth a spread yarn sheet | seat) opened by the opening apparatus 8. FIG.

  In the resin-impregnated portion 10, a resin composition containing a resin and an aluminum titanate-based ceramic sintered powder is thinly applied on the release paper 17 to create a resin-coated release paper.

  The resin-coated release paper 17 is supplied to the heat and pressure roll set 16 and another release paper 19 is supplied to the heat and pressure roll set 16 so as to sandwich the resin. The composition is impregnated. Next, after the base material sandwiched between the resin-coated release paper 17 and the release paper 19 is cooled by the cooling and pressing roll group 18, the release paper 19 is wound around the upper roll, and the prepreg sheet 20 is wound. Taken.

  In this way, in the method for producing a prepreg sheet using the above-described apparatus, the spread fiber sheet is stacked so that the arrangement (orientation) of the fiber bundle is not disturbed by overlapping the resin sheet on the spread fiber sheet aligned in one direction. A prepreg sheet is obtained by heating the resin to a temperature equal to or higher than the melting temperature of the resin while applying tension to the resin, melting the resin, and applying pressure to impregnate the spread yarn sheet with the resin.

The basis weight of the spread yarn sheet is preferably ²⁰ to 80 g / m ² , more preferably 20 to 50 g / m ² .

  The thickness of the produced prepreg sheet is preferably 20 μm to 180 μm, more preferably 30 μm to 160 μm.

  In addition, the method of opening another fiber bundle can also be employ | adopted in this invention.

  For example, (1) a method in which a fiber bundle to be conveyed is passed through a plurality of rollers while being bent, and the fiber bundle is pressed against a cylindrical substrate that vibrates in the axial direction therebetween (Japanese Patent Laid-Open No. 56). No. 43435), (2) A method in which a fiber bundle to be conveyed is vibrated in a longitudinal direction by a reciprocating body or a rotating body and then pressed onto a substrate having a curved surface to open the fiber bundle (Japanese Patent Application Laid-Open No. Sho 43). 61-275438), (3) a method of opening the conveyed fiber bundle by passing a group of rollers, a part of which is an eccentric rotating body (see JP-A-7-268754), etc. There is.

  As a method of impregnating the carbon fiber with the resin, other conventionally known methods can be employed in addition to the above method.

  For example, as shown in FIG. 2, a method of supplying the spread yarn sheet 3 obtained by the spread device 8 to a roll and continuously supplying a resin 5 onto the sheet 3, resin fibers on the spread yarn sheet A method of applying pressure while heating and heating the resin nonwoven fabric produced in step 1. Mixing while opening the spread yarn sheet and resin matrix fiber, spreading it into a sheet shape, and heat-sealing to produce a prepreg sheet And a method in which the spread yarn sheet is aligned in one direction to form a sheet, and the spread yarn sheet is introduced into a treatment bath containing a resin to adhere the resin.

  Hereinafter, the present invention will be described in more detail with reference to examples.

  The present invention is not limited to the examples as long as the gist thereof is not exceeded.

The materials and test methods used in the following examples are as follows.
(A) Carbon fiber used (A) -1 Carbon fiber: Pyrofil TR50S-15K (manufactured by Mitsubishi Rayon Co., Ltd.)
(A) -2 Carbon fiber: Trading card T800SC-24K (manufactured by Toray Industries, Inc.)
(B) Used resin and curing agent, etc. Epoxy resin: bisphenol A type epoxy resin (B) -1 jER828 (manufactured by JER Corporation)
(B) -2 jER1001 (manufactured by JER Corporation)
(B) -3 Hardener: Dicyandiamide jER Cure, DICY15 (manufactured by JER Corporation)
(B) -4 Curing accelerator: 3- (3,4-dichlorophenyl) -1,1-dimethylurea, DCMU99 (manufactured by Hodogaya Chemical Co., Ltd.)
(C) Preparation of used aluminum titanate ceramic sintered powder 43.9% by weight of anatase type titanium oxide (manufactured by Sakai Chemical Co., Ltd., A-110) and easily sintered alumina α type (Sumitomo Chemical Co., Ltd., Yaki) Calcium AES-11) 4 parts by weight of Fukushima alkali feldspar ((Na _0.39 K _0.61 ) AlSi ₃ O ₈ ) as an additive for 100 parts by weight of a mixture consisting of 56.1% by weight, 1.5 parts by weight of diethanolamine, 0.4 parts by weight of polyvinyl alcohol as a binder, and 30 parts by weight of water were added to obtain a raw material mixture. This raw material mixture was fired to obtain a sintered clinker of aluminum-based ceramic sintered powder, and this sintered clinker was pulverized for 48 hours by a ball mill and classified by a sieve. An aluminum titanate ceramic sintered powder having a sieve size of 1 to 5 μm and an average particle size x = 2.5 μm was prepared.
(D) Lightning strike simulation test As shown in FIGS. 3 and 4, the test apparatus used was a pair of test terminal plates connected to the cord 40 with a gap (10 mm) on the surface of the specimen 22 (molded body). 41 (SUS304) was placed, and current and voltage were applied between the two terminal boards 41. FIG. 5 shows the test equivalent circuit.

In FIG. 4, 22 is a specimen (molded body), 42 is a bakelite plate, and 43 is glass.
(E) Penetration test The penetration test apparatus shown in FIG. 6 was used.

In this apparatus, terminal rods 45, 45 are respectively arranged above and below the specimen (molded body) 22, a bolt 46 is screwed to the lower end of the upper terminal rod 45, and the upper end of the lower terminal rod 45 is attached. A disk metal plate 47 is attached. A voltage was applied between the upper and lower terminal bars 45, 45.
(F) Electrostatic Dissipation (ESI) Test As shown in FIGS. 7A and 7B, the surface of the 10 cm × 20 cm portion of the molded body 31 obtained in each example and comparative example was rubbed with nylon stockings. Static electricity was generated by carrying out (about 20-40 times), this molded object 31 was mounted on the copper plate, and the impulse voltage was measured with the oscilloscope.

The oscilloscope was manufactured by Yokogawa Electric Co., Ltd. (model DL-1640), with a frequency characteristic of 200 MHz and a maximum sample rate of 200 MS / s.
(G) Electrostatic voltage measurement test As shown in FIG. 8, the surface of the 10 cm × 20 cm portion of the molded body 31 obtained in each example and comparative example is rubbed with nylon stockings (about 20 to 40 times). Caused static electricity. An electrostatic voltage measuring device (STATIRON-M2, manufactured by Shishido electrostatic Co., Ltd.) 24 was disposed on the surface of the molded body 31 to measure the electrostatic voltage of the molded body.
(H) Capacitance measurement test As shown in FIG. 9, disk-shaped electrodes 26, 26 were respectively disposed on the front and back surfaces of the molded body 31 obtained in each of the examples and the comparative examples. The surface area of the electrode was 51.5 cm ² .

A capacitance measuring device (automatic sharing bridge, manufactured by Soken Denki Co.) 28 was connected between both electrodes as shown in FIG. 9, and the capacitance of the molded body was measured.
Example 1
Production of prepreg sheet in which aluminum titanate ceramic sintered powder is dispersed (A) Preparation of resin composition After stirring epoxy resin jER828 at a temperature of 80 ° C for 10 minutes in an agitator, epoxy resin jER1001 is contained therein. And stirred for another 10 minutes. The ratio of jER828 and jER1001 used was 4: 6 by weight.

  While stirring was continued, vacuum degassing was performed for 20 minutes. Thereafter, the aluminum titanate ceramic sintered powder was added in an amount of 1: 1 by weight with respect to the total amount of the epoxy resin, and stirring was continued for 20 minutes.

  Thereafter, the temperature was set to 60 ° C., and the curing agent DICY15 and the curing accelerator DCMU99 were added. 5 parts by weight of curing agent DICY15 and 2 parts by weight of curing accelerator DCMU99 were added to 100 parts by weight of the total amount of epoxy resin.

While vacuum degassing, stirring was performed at a temperature of 60 ° C. for 30 minutes to prepare an epoxy resin composition in which the aluminum titanate-based ceramic sintered powder was dispersed.
(B) Application of resin The epoxy resin composition obtained in (A) above is applied to release paper (WBE90R-DT, manufactured by Lintec Corporation) using Multicoater M-500 (Hirano Tech Seed Co., Ltd.). A resin-coated release paper was prepared by thinly coating. The application method was performed by a comma reverse method in which an epoxy resin composition was once applied to a coating roll, and the applied resin composition was thinly applied on a release paper.

Three types of coating weights of the epoxy resin composition on the release paper were prepared: approximately 34 g / m ² , approximately 42 g / m ² , and approximately 64 g / m ² . The prepared sheet was 330 mm wide × 200 m long.
(C) Preparation of prepreg sheet 1 Using the prepreg sheet manufacturing apparatus in which the fiber opening device and the resin-impregnated portion shown in FIG. 1 are continuously arranged, the aluminum titanate-based ceramic sintered powder was dispersed in the resin. A prepreg sheet 1 was produced.

  The opening device has a configuration in which an air opening portion, a longitudinal vibration applying portion, and a lateral vibration applying portion are installed. The resin-impregnated portion has a configuration in which two heating and pressing roll sets in which the heating and pressing rolls are combined vertically and two cooling and pressing roll groups in which the cooling and pressing rolls are combined in the vertical direction are continuous. And the epoxy resin composition can be continuously impregnated on one side of the sheet-like spread yarn sheet obtained by opening the fiber bundle obtained by the spreader.

  As the fiber bundle, carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; number of bundles 15,000) was used. The number of fiber bundles was 13, and the interval between fiber bundles was set to 24 mm. The initial tension applied to the fiber bundle was set to 150 g, and the fiber was transported at a transport speed of 5 m / min. The flow velocity of the suction airflow in the air opening portion (open state without fiber bundle) was 20 m / sec, and the hot air temperature blown out from the heating mechanism was 120 ° C.

  In the longitudinal vibration applying mechanism, the number of vibrations was 600 rpm, and the stroke amount of the roll pressing the fiber bundle was set to 10 mm. In the width direction vibration applying mechanism, the number of vibrations was 450 rpm, and the stroke amount for vibrating the spread yarn in the width direction was set to 5 mm.

  In addition, the diameter of the roll of the longitudinal vibration imparting mechanism is 10 mm, the diameter of the roll of the lateral vibration imparting mechanism is 25 mm, and each surface is subjected to a satin finish.

Setting as described above, the fiber bundle was conveyed to continuously produce a spread yarn sheet having a sheet width of about 310 mm. The basis weight of the spread yarn sheet was about 42 g / m ² .

Continuously, the spread yarn sheet was sandwiched between the resin composition-coated release paper having a basis weight of about 42 g / m ² and the upper release paper, and supplied to the heated and pressurized roll set. The temperature of the heating and pressing roll was set to 100 ° C., the cooling roll was set to water cooling, and the linear pressure of the heating and pressing roll was set to 10 kgf / cm. After discharging from the cooling roll, the upper release paper was taken up and the prepreg sheet attached to the lower release paper was taken up as a product sheet. The processing speed was 5 m / min.

A prepreg sheet 1 having a thickness of about 48 μm in which the aluminum titanate ceramic sintered powder was dispersed in the resin was obtained. The obtained prepreg sheet 1 had a carbon fiber basis weight of about 42 g / m ² and a calculated fiber volume content of about 50%.
(Example 2)
Preparation of prepreg sheet 2 As a fiber bundle, carbon fiber (manufactured by Toray Industries, Inc., Trading Card T800SC-24K; number of bundling 24,000) was used. The number of fiber bundles was 12, and the interval between fiber bundles was set to 27 mm. Initial tension applied to the fiber bundle, conveyance speed, flow velocity of the suction airflow in the air opening section, hot air temperature blown from the heating mechanism, number of vibrations of the longitudinal vibration applying mechanism, stroke amount of the roll pressing the fiber bundle, width The number of vibrations of the directional vibration applying mechanism, the stroke amount for vibrating the spread yarn in the width direction, and the like were set to be the same as the conditions of Example 1.

Setting as described above, the fiber bundle was conveyed to continuously produce a spread yarn sheet having a sheet width of about 320 mm. The basis weight of the spread yarn sheet was about 38 g / m ² .

Continuously, the spread yarn sheet was sandwiched between the resin-coated release paper having a weight of about 34 g / m ² , the release paper, and the upper release paper, and supplied to the heated and pressurized roll set. The setting conditions such as the heating and pressing roll and the cooling and pressing roll and the processing speed were also set to be equivalent to those in Example 1.

  After discharging from the cooling roll, the upper release paper was taken up and the prepreg sheet attached to the lower release paper was taken up as a product sheet.

A prepreg sheet 2 having a thickness of about 40 μm in which the aluminum titanate ceramic sintered powder was dispersed in the resin was obtained. The obtained prepreg sheet 2 had a carbon fiber basis weight of about 38 g / m ² and a calculated fiber volume content of about 52%.
(Example 3)
Preparation of prepreg sheet 3 As a fiber bundle, carbon fiber (manufactured by Mitsubishi Rayon Co., Ltd., Pyrofil TR50S-15K; 15,000 bundles) was used. The number of fiber bundles was 40, and the interval between fiber bundles was set to 8 mm.

In this example, the fiber opening mechanism was not used, and the fiber bundle was directly supplied to the resin-impregnated part. The initial tension of the fiber bundle was set to 150 g, and the fiber bundle was conveyed at a conveyance speed of 5 m / min. The carbon fiber sheet width was about 320 mm, and the basis weight was about 128 g / m ² .

Continuously, a plurality of carbon fiber bundles arranged in the width direction are sandwiched up and down with a resin-coated release paper having a basis weight of about 64 g / m ² prepared in (B) of Example 1 and supplied to a heated and pressurized roll set. did. Unlike the cases of Examples 1 and 2, the resin-coated release paper was set up and down so that the basis weight of the resin was about 128 g / m ² .

  About setting conditions, such as a heating pressurization roll and a cooling roll, and the pressurization speed, it was set equivalent to Example 1 and 2. FIG.

  After discharging from the cooling roll, the upper release paper was taken up and the prepreg sheet attached to the lower release paper was taken up as a product sheet.

A prepreg sheet 3 having a thickness of about 142 μm in which the aluminum titanate ceramic sintered powder was dispersed in the resin was obtained. The obtained prepreg sheet 3 had a carbon fiber basis weight of about 128 g / m ² and a calculated fiber volume content of about 50%.
(Comparative Example 1)
Preparation of Prepreg Sheet 4 The prepreg sheet 4 (thickness: 125 μm) is a normal prepreg sheet in which aluminum titanate ceramic sintered powder is not dispersed, and was prepared by the following method.
(A) Preparation of material The carbon fiber bundle used was Pyrofil TR50S-15K (manufactured by Mitsubishi Rayon Co., Ltd.), and the epoxy resin was blended with jER828 and jER1001 at a weight ratio of 4: 6, as in Example 1. Resin was used.

An epoxy resin mixture was prepared in the same manner as in Example 1 (A: Preparation of resin composition) except that the aluminum titanate ceramic sintered powder was not added to the resin.
(B) Application of resin In the same manner as the resin application method described in Example 1, an epoxy resin of about 31 g / m ² was applied on release paper (WBE90R-DT, manufactured by Lintec Corporation). A resin-coated release paper was prepared.
(C) Preparation of prepreg sheet 4 A prepreg sheet 4 having a thickness of about 125 μm was prepared in the same manner as in Example 3.

That is, after 40 carbon fibers TR50S-15K were arranged at an 8 mm pitch, a resin-coated release paper was sandwiched from above and below to prepare a prepreg sheet 4 having a thickness of 125 μm. The prepared prepreg sheet 4 had a carbon fiber basis weight of about 128 g / m ² and a calculated fiber volume content of about 58%.
Example 4
Thin layer ceramic / thick layer / thin layer ceramic laminate (thickness 5.3 mm)
The prepreg sheet 1 (thickness 48 μm) prepared in Example 1 was used, the prepreg sheet was cut out, and a total of 24 cut prepreg sheets 1 were laminated with [0/90] 12 to form a first prepreg laminate. Got. The thickness was about 1.15 mm.

  Using the prepreg sheet 4 (thickness 125 μm) prepared in Comparative Example 1 above, the prepreg sheet 4 was cut out, and a total of 24 cut prepreg sheets 4 were laminated with [0/90] 6S to obtain the second prepreg lamination. The material was obtained. The thickness was about 3 mm.

  The prepreg sheet 1 (thickness 48 μm) prepared in Example 1 was used, the prepreg sheet was cut out, and a total of 24 prepreg sheets 1 were laminated with [90/0] 12 to form a third prepreg laminate. Got. The thickness was about 1.15 mm.

  A second prepreg laminate is laminated on the first prepreg laminate, and a third prepreg laminate is further laminated thereon to form a carbon fiber reinforced composite material, which is set in an autoclave apparatus, 130 ° C., 0.5 MPa Molding was performed for 2 hours under the above processing conditions, and the epoxy resin was cured to produce a 30 cm × 30 cm flat plate-shaped molded body having a thickness of about 5.3 mm.

In the obtained molded body, in order from the lower layer, a layer having a thickness of 48 μm was oriented 12 times in a fiber direction of 0 degree and 90 degrees, and a total of 24 layers were laminated, and then a layer having a thickness of 125 μm was 0 degree in the fiber direction. A total of 12 layers are laminated 6 times oriented in the direction of 90 degrees, and then a layer of 125 μm thickness is laminated in a total of 12 layers 6 times oriented 90 degrees in the fiber direction and 0 degrees, and finally the thickness A 48 μm layer was oriented 12 times in the fiber direction 90 degrees and 0 degrees, and a total of 24 layers were laminated.
(Example 5)
Thick layer ceramic / thick layer / thick layer ceramic laminate (thickness 5.3 mm)
Using the prepreg sheet 3 (thickness 142 μm) prepared in Example 3 above, the prepreg sheet was cut out, and a total of eight prepreg sheets 3 cut out with [0/90] 4 were laminated to form a first prepreg laminated material Got. The thickness was about 1.16 mm.

  Using the prepreg sheet 4 (thickness 125 μm) prepared in Comparative Example 1 above, the prepreg sheet 4 was cut out, and a total of 24 cut prepreg sheets 4 were laminated with [0/90] 6S to obtain the second prepreg lamination. The material was obtained. The thickness was about 3 mm.

  Using the prepreg sheet 3 (thickness 142 μm) prepared in Example 3 above, the prepreg sheet was cut out, and a total of eight prepreg sheets 3 cut out with [90/0] 4 were laminated to form a third prepreg laminated material Got. The thickness was about 1.16 mm.

A second prepreg laminate is laminated on the first prepreg laminate, and a third prepreg laminate is further laminated thereon to form a carbon fiber reinforced composite material, which is set in an autoclave apparatus, 130 ° C., 0.5 MPa Molding was performed for 2 hours under the above processing conditions, and the epoxy resin was cured to produce a 30 cm × 30 cm flat plate-shaped molded body having a thickness of about 5.3 mm.
(Example 6)
Thin layer ceramics / vertam plate / thin layer ceramic laminate (thickness approx. 7mm)
Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out, and a total of 24 cut out prepreg sheets 2 were laminated with [0/90] 12 to obtain the first prepreg laminated material Got. The thickness was about 1 mm.

  A general commercial product (composite product with a 5 mm-thick fabric laminate (epoxy resin)) was used as the bartam plate.

  Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out and a total of 24 prepreg sheets 2 were laminated with [90/0] 12 to obtain a second prepreg laminate. Got. The thickness was about 1 mm.

Overlay the first prepreg laminate with a bar tam plate, and then overlay the second prepreg laminate with a carbon fiber reinforced composite material, set it in an autoclave, and process conditions of 130 ° C and 0.5 MPa. Then, molding was performed for 2 hours, and the epoxy resin was cured to produce a 30 cm × 30 cm plate-shaped molded body having a thickness of about 7 mm.
(Example 7)
Thin layer ceramics / vertam plate / thin layer ceramic laminate (thickness approx. 6 mm)
Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out, and a total of 24 cut out prepreg sheets 2 were laminated with [0/90] 12 to obtain the first prepreg laminated material Got. The thickness was about 1 mm.

  A general commercial product (composite product with a 4 mm-thick fabric laminate (epoxy resin)) was used as the bartam plate.

  Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out and a total of 24 prepreg sheets 2 were laminated with [90/0] 12 to obtain a second prepreg laminate. Got. The thickness was about 1 mm.

Overlay the first prepreg laminate with a bar tam plate, and then overlay the second prepreg laminate with a carbon fiber reinforced composite material, set it in an autoclave, and process conditions of 130 ° C and 0.5 MPa. Then, molding was performed for 2 hours, and the epoxy resin was cured to produce a 30 cm × 30 cm plate-shaped molded body having a thickness of about 6 mm.
(Example 8)
Molded body having resin composition layer on surface The resin composition was applied by hand on the surface of the carbon fiber reinforced composite material prepared in Example 7 to form a resin composition layer having a thickness of about 0.5 mm. The resin composition obtained the epoxy resin composition like Example 1 (A) except having made the ratio of ceramics and an epoxy resin into 80 weight part: 100 weight part.

This carbon fiber reinforced composite material is set in an autoclave and molded for 2 hours under processing conditions of 130 ° C. and 0.5 MPa, and the epoxy resin is cured to form a flat plate shape of 30 cm × 30 cm having a thickness of about 6.5 mm. A molded body was prepared.
Example 9
Thin layer ceramics / vertam plate / thin layer ceramic laminate (thickness approx. 3 mm)
Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out, and a total of 24 cut out prepreg sheets 2 were laminated with [0/90] 12 to obtain the first prepreg laminated material Got. The thickness was about 1 mm.

  A general commercial product (composite product with a 1 mm-thick fabric laminate (epoxy resin)) was used as the bartam plate.

  Using the prepreg sheet 2 (thickness 40 μm) prepared in Example 2 above, the prepreg sheet was cut out and a total of 24 prepreg sheets 2 were laminated with [90/0] 12 to obtain a second prepreg laminate. Got. The thickness was about 1 mm.

Overlay the first prepreg laminate with a bar tam plate, and then overlay the second prepreg laminate with a carbon fiber reinforced composite material, set it in an autoclave, and process conditions of 130 ° C and 0.5 MPa. Then, molding was performed for 2 hours to cure the epoxy resin, and a 30 cm × 30 cm plate-shaped molded body having a thickness of about 3 mm was prepared.
(Example 10)
An epoxy resin composition was obtained in the same manner as in Example 1 except that 140 parts by weight of the aluminum titanate ceramic sintered powder was used with respect to 100 parts by weight of the epoxy resin, and the prepreg sheet 5 was obtained from this resin composition. Got.

Except using this prepreg sheet 5, it carried out similarly to Example 4, and created the 30-cm x 30-cm plate-shaped molded object of thickness about 5.3 mm.
(Example 11)
An epoxy resin composition was obtained in the same manner as in Example 1 except that 60 parts by weight of the aluminum titanate-based ceramic sintered powder was used with respect to 100 parts by weight of the epoxy resin, and the prepreg sheet 6 was obtained from this resin composition. Got.

Except using this prepreg sheet 6, it carried out similarly to Example 4, and produced the molded object of the flat shape of 30 cm x 30 cm of thickness about 5.3 mm.
(Example 12)
An epoxy resin composition was obtained in the same manner as in Example 1 except that 200 parts by weight of the aluminum titanate ceramic sintered powder was used with respect to 100 parts by weight of the epoxy resin, and the prepreg sheet 7 was obtained from this resin composition. Got.

A 30 cm × 30 cm flat plate-shaped compact having a thickness of about 5.3 mm was prepared in the same manner as in Example 4 except that this prepreg sheet 7 was used.
(Example 13)
The sintered clinker obtained in the same manner as in the preparation (C) of the aluminum titanate ceramic sintered powder of the example was pulverized for 48 hours by a ball mill and classified by a sieve. An aluminum titanate ceramic sintered powder having a sieve size of 10 to 30 μm and an average particle size x = 15 μm was prepared.

Except for using this aluminum titanate-based ceramic sintered powder, a 30 cm × 30 cm flat plate-shaped compact having a thickness of about 5.3 mm was prepared in the same manner as in Example 4.
(Comparative Example 2)
Preparation of molded body (thickness: about 5 mm) 20 sheets of 30 cm × 30 cm, using the prepreg sheet 4 having a thickness of 125 μm obtained in (C) of Comparative Example 1 above and having the fiber direction of the prepreg sheet as 0 degree. Then, 20 sheets of 30 cm × 30 cm having a fiber direction of 90 degrees were cut out and laminated in a configuration of [0/90] 10S.

This prepreg laminate is set in an autoclave apparatus, molded for 2 hours under the processing conditions of 130 ° C. and 0.5 MPa, the epoxy resin is cured, and a 30 cm × 30 cm flat molded body having a thickness of about 5 mm is obtained. Created.
(Lightning strike simulation test results)
Using the molded bodies obtained in Example 4-13 and Comparative Example 2, a lightning strike simulation test was performed using the impulse voltage generator (specification: 20,000 V / 25,000 A rating) shown in FIG. 3-4.

  The test conditions were as follows.

Gap length: 10mm
Applied waveform: 10/350 μs
Setting current: 25KA
The measured current value and the charging voltage were as follows.

  In Example 4, the measured current value was 24.6 KA, and the charging voltage was 21.2 KV.

  In Example 5, the measured current value was 25.0 KA, and the charging voltage was 21.2 KV.

  In Example 6, the measured current value was 25.0 KA, and the charging voltage was 21.2 KV.

  In Example 7, the measured current value was 24.5 KA, and the charging voltage was 21.2 KV.

  In Example 8, the measured current value was 24.3 KA and the charging voltage was 21.2 KV.

  In Example 9, the measured current value was 24.5 KA, and the charging voltage was 21.2 KV.

  In Examples 10-13, the measured current value was 24.5 KA and the charge voltage was 21.2 KV.

  When the applied voltage (20 KV / 25 KA = 625 KW) was discharged to the test body (molded body) obtained in Example 4-13, lightning was discharged at 10 mm between the terminal plates on the surface of the test body. There was no damage that would cause damage such as damage at all. When discharging between the test terminal plates, the stainless steel (SUS304) was melted. The generation temperature seems to be about 1350 ° C to 1,500 ° C.

  When the test body (molded body) obtained in Comparative Example 2 was discharged in the same manner as described above, lightning was discharged at 10 mm between the terminal boards on the surface of the test body, and the test body was greatly damaged.

  The Joule heat (KJ) obtained with the applied voltage / current is calculated by the following equation.

The resistance between the front and back surfaces of the molded body of Example 7 was 22 ohms, and the resistance at the center was 12 ohms.

  The resistance of the resin composition layer on the surface of the molded article of Example 8 was 3.065 T ohm (3,065 M ohm).

  FIG. 10 shows an applied waveform of a lightning impulse current test of the molded body obtained in Example 7. The current value was 24.5 KA.

  FIG. 11 shows an applied waveform of a lightning impulse current test of the molded body obtained in Example 8. The current value was 24.3 KA.

  FIG. 12 shows an applied waveform of a lightning impulse current test of the molded body obtained in Example 9. The current value was 24.5 KA.

  Moreover, the impulse waveform of the discharge voltage implemented using the lightning strike simulation test apparatus used in the present invention is shown in FIG. 13A, and the impulse waveform of the discharge voltage implemented using a typical lightning strike simulation test apparatus is shown in FIG. As shown in FIG.

  As can be seen from these waveforms, the lightning strike simulation test apparatus used in the present invention can obtain an applied voltage about 25 times that of a general lightning strike simulation test apparatus.

From the above, it can be seen that the molded article of the present invention can be expected to have a barrier effect from the ignition temperature (about 1,500 ° C.) due to instantaneous lightning energy during lightning strikes.
(Penetration test result)
Using the penetration test apparatus shown in FIG. 6, a penetration test was performed under the following conditions.

Applied waveform: 10/350 μs
Setting current: 25KA
In Example 7, the measured current value was 23.8 KA, and the charging voltage was 21.2 KV.

  In Example 9, the measured current value was 23.8 KA, and the charging voltage was 21.2 KV.

  In Examples 4-6, 8, and 10-13, the measured current value was 23.8 KA, and the charging voltage was 21.2 KV.

  As a result of the penetration experiment, the molded body obtained in Example 4-13 was not seen to penetrate between the terminal local portions.

  The molded body obtained in Comparative Example 2 showed penetration. The surface of the molded body was damaged in a wide range, the holes were greatly opened, and the carbon fiber yarns were peeled apart and rolled up.

  In the molded body obtained in Example 4-13, a plane compression mark of the ground side terminal (disk shape) was seen on the back side, but it was not penetrated, and it was penetrated even in non-destructive inspection by X-rays. I knew it was n’t there.

  In FIG. 14, the waveform in the penetration direction of the molded object obtained in Example 9 was shown. The current value was 23.8 KA.

In FIG. 15, the waveform in the penetration direction of the molded object obtained in Example 7 was shown. The current value was 23.8 KA.
(Electrostatic dissipation (ESI) test results)
The test results are shown in FIGS. 16-20.

  FIG. 16 is a measurement value at 5 v / div of the molded body obtained in Comparative Example 2, and shows that the minimum value is 26.7V.

  FIG. 17 is a measurement value at 10 v / div of the molded body obtained in Comparative Example 2, and shows that the maximum value is 61.5V.

  FIG. 18 shows the measured value at 5 v / div of the molded body obtained in Example 4, and shows that the maximum value is 23.3V.

  FIG. 19 shows the measured value at 5 v / div of the molded body obtained in Example 5, and shows that the maximum value is 13.1V.

  FIG. 20 shows the measured value at 5 v / div of the molded body obtained in Example 6, and shows that the minimum value is 0.5V.

The following can be seen from FIG.
(1) In the case of a CFRP-only plate, the maximum is 61.5V and the minimum is 26.7V.
(2) In the case of a CFRP ceramic composite plate, the maximum is 13.1V and the minimum is 0.5V.

  From the above results, it was found that the amount of electrostatics was clearly smaller in the composite plate with ceramics than in the case of only CFRP.

In the case of an aircraft, for example, A-350 (Airbus), CFRP is used in about 50% of the airframe. As an example, CFRP is about 440 m ^{2 in} surface area. The electrostatic capacity charged here is considerable, and the impulse voltage at the time of spark is very dangerous. On the other hand, it can be said that the molded body of the present invention is safe because the electrostatic capacitance to be charged is small.

From this test result of the above-mentioned embodiment, it was found that there is a difference in charging rate of 51.5 times when the maximum 61.5 V: the highest 13.1 V is 4.7 times and the minimum 26.7 V: the minimum 0.5 V is 53.4 times.
(Electrostatic voltage measurement test results)
When the electrostatic voltage of the molded body was measured, the electrostatic voltage of the molded body of Example 4 was 500V, and the electrostatic voltage of the molded body of Example 5 was 500V.

In the molded bodies of Examples 4 and 5, the electrostatic impulse voltage on the surface was generated, but the capacitance value was equal to 0 because the resistance value of CFRP (surface layer) was low. Therefore, it can be seen from the calculation of energy 1/2 CV ^{2 that} the energy is 0, and as a result, no charging is performed. The results of the molded bodies of Examples 4 and 5 were the same as those of the molded bodies of other Examples.
(Capacitance measurement test results)
When the electrostatic capacity of the molded body was measured, the electrostatic capacity of the molded body of Example 4 was 0 coulomb (unmeasurable), and the electrostatic capacity of the molded body of Example 5 was 0 coulomb (unmeasurable). The results of the molded bodies of Examples 4 and 5 were the same as those of the molded bodies of other Examples.

  According to the present invention, automobiles such as buses, trucks, passenger cars, and special vehicles; railway vehicles such as trains, trains, high-speed railway vehicles, and linear motor car vehicles; passenger ships, cargo ships, tankers, pleasure boats, hydrofoil ships, It can be suitably used as a structural material such as a moving body such as a submarine and a ship such as a submarine, a container, a chemical plant, a gas cylinder, and a tank of oil.

2 Carbon fiber bundle 3 Opened carbon fiber 6 Winding part 8 Opening device 10 Resin impregnation part 12 Opening part 13 to open the fiber 13 Vertical vibration giving part 14 Lateral vibration giving part 16 Heating and pressing roll group 17 Release paper 18 Cooling and pressing roll group 19 Separate release paper 20 Pre-preg sheet

Claims (11)

In a molded article for an automobile of a carbon fiber reinforced composite material using carbon fiber as a reinforcing material and using a resin composition as a matrix,
The resin composition comprises 100 parts by weight of resin and ultra low expansion titanic acid having a linear expansion coefficient of −0.3 × 10 ⁻⁶ / K to −1 × 10 ⁻⁶ / K at −40 ° C. to + 1350 ° C. contains a sintered powder 60 to 200 parts by weight of aluminum-based ceramic, shaped bodies for a motor vehicle the aluminum titanate-based ceramic sintered powder is dispersed in the resin in at least the surface layer of the molded article . 2. The molded article for automobile according to claim 1 , wherein the aluminum titanate-based ceramic sintered powder has an average particle diameter of 0.001 to 100 μm. The molded article for automobiles according to claim 1 or 2 , wherein the aluminum titanate-based ceramic sintered powder is obtained by firing and pulverizing a molded article formed from a raw material containing titanium dioxide, alumina and alkali feldspar. The molded article for automobiles according to any one of claims 1 to 3 , wherein the resin is a thermosetting resin, a thermoplastic resin, or a mixture of a thermosetting resin and a thermoplastic resin. The carbon fiber is a carbon fiber that is aligned in one direction, and a plurality of resin-impregnated fiber layers obtained by impregnating the carbon fiber with the resin composition are laminated in the thickness direction to form the carbon fiber reinforced composite material. Formed,
The and carbon fibers oriented in one direction in each of the resin-impregnated fiber layers, carbon fibers are oriented in multiple directions as a whole of the plurality of resin-impregnated fibrous layer, any one of claims 1-4 The molded object for motor vehicles described in 2. The molded article for automobiles according to claim 5 , wherein the thickness of each resin-impregnated fiber layer is 20 to 80 µm. The molded object for motor vehicles of Claim 5 or 6 in which the resin composition layer which consists of the said resin composition is provided between the said resin impregnation fiber layer and the resin impregnation fiber layer. The carbon fibers are carbon fibers aligned in one direction, and a plurality of resin-impregnated fiber layers obtained by impregnating the carbon fibers with a resin are laminated in the thickness direction to constitute a carbon fiber reinforced composite material,
In each of the resin-impregnated fiber layers, the carbon fibers are oriented in one direction, and as a whole of the plurality of resin-impregnated fiber layers, the carbon fibers are oriented in multiple directions,
The molded object for motor vehicles of any one of Claims 1-4 in which the resin composition layer which consists of the said resin composition is provided between this resin impregnation fiber layer and the resin impregnation fiber layer. Furthermore, it has a core material, The molded object for motor vehicles of any one of Claims 1-8 in which the said carbon fiber reinforced composite material is arrange | positioned on the at least single side | surface of this core material. The molded article for automobiles according to claim 9 , wherein the core material is a carbon fiber reinforced composite material using carbon fibers as a reinforcing material and using a resin as a matrix. The molded object for motor vehicles of any one of Claims 1-10 with which the resin composition layer formed by apply | coating the said resin composition is provided in the at least single side | surface of the said carbon fiber reinforced composite material. .