JP5725192B2 - 繊維強化複合材料構造体を用いた複合材料成形体、ならびにその製造方法 - Google Patents
繊維強化複合材料構造体を用いた複合材料成形体、ならびにその製造方法 Download PDFInfo
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- JP5725192B2 JP5725192B2 JP2013535604A JP2013535604A JP5725192B2 JP 5725192 B2 JP5725192 B2 JP 5725192B2 JP 2013535604 A JP2013535604 A JP 2013535604A JP 2013535604 A JP2013535604 A JP 2013535604A JP 5725192 B2 JP5725192 B2 JP 5725192B2
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Landscapes
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- Lining Or Joining Of Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
本願は、2012年7月18日に、日本に出願された特願2012−159553号及び2013年4月9日に、日本に出願された特願2013−081019号、に基づき優先権を主張し、その内容をここに援用する。
前記複数の凸部のうち一つの凸部において、前記凸部の頂面の形状及び前記凸部と前記第一面との境界線で囲まれる第1領域の形状が、正方形、長方形、菱形、三角形、五角形、六角形、円形、楕円形、丸角正方形、丸角長方形、丸角菱形、丸角三角形、丸角五角形、及び丸角六角形から選択される少なくとも1種であることが好ましい。
前記複数の凸部は、一つの第1凸部と、前記第1凸部に隣り合う第2凸部とを有し、前記第一面と垂直な方向における前記第1凸部の中心軸と、前記第2凸部の中心軸との間隔によって凸部ピッチが規定され、前記凸部ピッチが前記第1領域の最小径の1.6〜2.4倍であることが好ましい。
前記複数の凸部が規則的に設けられた第2領域において、前記第2領域の面積がαで定義され、前記複数の凸部の前記頂面の面積の合計がβで定義され、比β/αが5%以上40%未満であることが好ましい。
前記複数の凸部のうち一つの凸部において、前記凸部の頂面の面積が前記薄板の板厚の2乗の5倍以上〜500倍未満であることが好ましい。
前記複数の凸部の高さが前記薄板の板厚の0.5倍以上10倍未満であることが好ましい。
前記薄板は強化繊維を含み、前記複数の凸部の配列が、前記強化繊維における繊維の長さ方向に対して0°および90°方向に配列する正方配列ならびに長方配列、または前記複数の凸部の配列方向が前記繊維の長さ方向に対して角度をなす千鳥配列から選択される少なくとも1種の配列を含むことが好ましい。
前記複数の凸部の各々において、前記頂面に平行な方向の断面における最小値フェレ径が、前記薄板の板厚の3倍以上30倍未満であることが好ましい。
前記複数の凸部の各々の先端部に凹状の窪みを有することが好ましい。
本発明の第二態様の複合材料成形体においては、前記第一態様の繊維強化複合材料構造体と前記樹脂構造体との接合界面に設けられた接着剤層を有することが好ましい。
前記樹脂構造体が熱可塑性樹脂を含むことが好ましい。
前記樹脂構造体がさらにガラス繊維を含むことが好ましい。
本発明の第三態様にかかる複合材料成形体の製造方法は、強化繊維と熱硬化性樹脂組成物とを含むプリプレグ積層体を準備し、突起または窪みを有する型を用いて前記プリプレグ積層体を加熱加圧して、複数の凸部を有する薄板を作製し、前記薄板の前記凸部の頂面に表面材を接合することで繊維強化複合材料構造体を作製し、樹脂材料を前記薄板と前記表面材との間に注入射出して、前記樹脂材料を含む樹脂構造体と前記繊維強化複合材料構造体とを接合する。
また、本発明の第三態様は、このような複合材料成形体の製造方法である。
なお、表面材1および薄板2の作製に用いるマトリクス樹脂として、熱可塑性樹脂を用いた場合には、接着剤3を用いて表面材1と薄板2とを接着接合する代わりに、表面材1と薄板2とを融着接合することも可能である。
なお、表面材1および薄板2の作製に用いるマトリクス樹脂として、熱可塑性樹脂を用いた場合には、接着剤3を用いて表面材1と薄板2とを接着接合する代わりに、表面材1と薄板2とを融着接合してもよい。
本発明の第1実施形態にかかる薄板2は、ベース部14(薄板2において、基底面である第一面を有する基底部)と1つ以上の凸部11を含む。凸部11は、頂面部(頂面)12、および頂面部12とベース部14とをつなぐ接続面13(凸部11の側面)から形成される。なお、前記第一面は、薄板2において、凸部11が形成された側のベース部14の一面を意味する。また、表面材において、前記頂面部(頂面)12と接合する側の面を第二面と呼ぶ。
本発明の第1実施形態にかかる薄板2に形成する複数の凸部11の頂面部12の形状は特に限定されず、正方形、長方形、菱形、三角形、円形、楕円形、五角形、および六角形などを用いることができる。正方形、長方形、菱形、三角形、五角形、および六角形においては、これらの角の少なくとも1つが丸角であってもよい。これらの形状から選択される1種類の形でもよく、複数の形又はサイズが混合してもよい。
なお、凸部11のピッチPは、薄板2のベース部14(薄板2の第一面を有する基底部)と垂直な方向における凸部11(第1凸部)の中心軸G1(第1凸部の重心の位置)と、前記凸部11(第1凸部)に隣り合う凸部11(第2凸部)の中心軸G2(第2凸部の重心の位置)との間隔として規定される(図37)。第1凸部に隣り合う凸部11(第2凸部)とは、第1凸部以外の凸部11であって、その中心軸(該凸部11の重心の位置)と中心軸G1(第1凸部の中心軸)との距離が最も短い凸部11を意味する。
凸部11のサイズW1は、凸部11の底面(頂面の反対に位置する凸部の底面としての仮想面である第1領域、凸部とベース部14(薄板2の第一面を有する基底部)との境界線で囲まれる第1領域)の径で規定できる。この場合における凸部11のサイズW1は、凸部11の底面(第1領域)が円形の場合には、底面の直径として規定される。例えば、凸部11の底面(第1領域)が円形である場合には、凸部11のサイズW1は、凸部11と薄板2のベース部14(薄板2の第一面を有する基底部)との境界線で囲まれる領域である底面(第1領域)の最小径(直径)として規定される。
凸部11の底面(第1領域)が楕円形の場合には長径と短径の平均値として規定される。凸部11の底面(第1領域)が正方形および長方形の場合には、対角線の長さとして規定される。凸部11の底面(第1領域)が菱形の場合には2つの対角線の長さの平均値として規定される。凸部11の底面(第1領域)が三角形、五角形、および六角形の場合には最小外接円の直径として規定される。
この場合における凸部11のピッチPも、薄板2のベース部14(薄板2における第一面を有する基底部)と垂直な方向における凸部11の中心軸(第1凸部の中心軸)と、前記凸部11に隣り合う凸部11の中心軸(第2凸部の中心軸)との間隔として規定される。
<薄板の成形>
まず、強化繊維に熱硬化性樹脂組成物を含浸したプリプレグの積層体を、薄板用の下型8表面に配置する。薄板用の下型8は薄板2の凸部11または凸条15となる部分が突起9、および10(図2)または窪み(図示しない)を有している。
突起を有する下型8を用いる場合には、プレス成形法の上型は、薄板2の凸部11または凸条15となる部分が凹形状となっている型を用いることができる。また、窪みを有する下型8を用いる場合には、プレス成形法の上型には、薄板2の凸部11または凸条15となる部分が凸形状となっている型を用いることもできる。圧縮により下型8の突起または窪みに沿って凹形状または凸形状となる軟質材料を用いる場合には、上型の成型面に凸形状または凹形状を設ける必要はない。なお、真空バッグ成形法の場合は上型を用いない。
薄板2の成形と同様にして、表面材1を得る。但し表面材は平面ないしは単純な曲面であるので表面材用の下型8は平面形状ないし単純な曲面の形状である。なお、表面材1の形状は、PC筐体のデザイン等に応じ、ロゴの凹みなどの段差や角(稜線)を有する形状も可能であり、用途に応じて選択してもよい。さらに、表面材1の形状に応じて、薄板2の形状を決定してもよい。
表面材1と薄板2については、表面材1と薄板2とをそれぞれ成形した後に接合するため、反り防止のために対称構成としなくともよい。表面材1のみには、織布など加飾材を使用することができる。また、表面材1および薄板2には、適宜、難燃性樹脂材料を使用してもよい。
薄板2の凸部11の頂面部12及び凸条15の上面16、又は凸部11の先端部(頂面)18の凹状の窪み19及び凸条の先端(上面)20の窪み21に接着剤3を塗布し、薄板2と表面材1とを合わせた後に接着剤3を硬化して、繊維強化複合材料構造体6を得る。
(実施例1)
本実施例においては、一方向プリプレグとして、三菱レイヨン(株)製、製品名:TR390E125S(熱硬化性樹脂:エポキシ樹脂#390(三菱レイヨン(株)製)、強化繊維:炭素繊維(三菱レイヨン(株)製、製品名:TR50S))を用いた。
なお、上記0°とは、表面材1または薄板2が長方形の場合、それぞれの短辺方向を0°方向と定義した場合を意味する。
上記90°とは、上記0°方向と直交した表面材1または薄板の長辺方向(90°方向)を意味する。
表面材1または薄板2が長方形以外の場合は、最小値フェレ径方向を0°方向と定義し、90°方向は当該0°方向と直交した方向を意味する。
(実施例2)
シミュレーションソフトとして、Femap with NX Nastranを使用し、支持条件は単純支持として実施した。
本実施例の薄板2および表面材1は、一方向プリプレグ 三菱レイヨン(株)製、製品名:TR390E125S(熱硬化性樹脂:エポキシ樹脂#390(三菱レイヨン(株)製)、強化繊維:炭素繊維(三菱レイヨン(株)製、製品名:TR50S))を[0°/90°/0°]の配置となるように3層積層し、積層体を140℃で加熱しながら8MPaの圧力で5分間プレスして硬化することで成形される。
(実施例3)
(実施例4)
(比較例1)
(比較例2)
(比較例3)
(実施例5)
(実施例6)
(実施例7)
(実施例8)
(実施例9)
(実施例10)
(実施例11)
(実施例12)
(実施例13)
(実施例14)
(実施例15)
(実施例16)
(実施例17)
(実施例18)
(実施例19)
(実施例20)
(実施例21)
(実施例22)
(実施例23)
(実施例24)
(実施例25)
(実施例26)
一方で、凸部ピッチPが8mm以下および12mm以上においては、撓み量が大きくなり、剛性が大きく低下する。
凸部11を有する薄板2と表面材1構造体が接着剤3で接着される繊維強化複合材料構造体6として、円柱凸部においては、凸部ピッチPが凸部サイズW1の1.6〜2.4倍であることが望ましい。
また、いずれの配列においても最小撓み量はほぼ同じであり、正方配列および千鳥配列においては優れた剛性効果が得られる。
また、千鳥配列では繊維の長さ方向における断面長の差が正方配列よりも短くなるため、成形性が向上する。
実施例27〜38では凸部11の形状を楕円形に変更した。
(実施例27)
楕円の短径は5mm、長径は7.5mmとし、凸部ピッチPは10mmに変更する。
(実施例28)
(実施例29)
(実施例30)
(実施例31)
短径を5mm,長径を10mmとし、凸部ピッチPは12mmとする。
(実施例32)
(実施例33)
(実施例34)
(実施例35)
楕円の短径は5mm、長径は7.5mmとし、凸部ピッチPは9mmとする。
(実施例36)
(実施例37)
(実施例38)
凸部11が楕円形においては、凸部ピッチPが、楕円形の短径と長径の平均値の約2倍となる範囲で剛性が最大となり、1.6〜2.4倍の範囲で良好な剛性効果が得られる。
また、楕円の長径と短径の比が大きくなると最大撓み量が増え剛性効果が劣るため、楕円形の凸部11においては、長径が短径の1.5倍以下であることが望ましい。
(実施例39)
正方形の対角線は5mmとし、凸部ピッチPは6mmとする。
(実施例40)
(実施例41)
(実施例42)
凸部11の形状が正方形において、正方形の対角線5mmに対して、凸部ピッチPが7〜10mmの範囲で優れた剛性効果が得られる。
凸部11が正方形においては、凸部ピッチPが正方形の対角線の1.4〜2.0倍であることが望ましい。
(実施例43)
(実施例44)
(実施例45)
(実施例46)
凸部11の形状が45°傾き正方形である場合において、正方形の対角線5mmに対して凸部ピッチPが8〜10mmの範囲で優れた剛性効果が得られる。
凸部11の形状が45°傾き正方形においては、凸部ピッチPが正方形の対角線の1.6〜2.0倍であることが望ましい。
(実施例47)
正六角形の外接円を5mmとし、凸部ピッチPは6mmとする。
(実施例48)
(実施例49)
(実施例50)
凸部11の形状が正六角形においては、外接円5mmに対して、凸部ピッチPが8〜12mmの範囲で効果的な剛性効果が得られる。
凸部11の形状が正六角形においては、凸部ピッチPが正六角形の外接円の1.6〜2.4倍であることが望ましい。
(実施例52)
(実施例53)
(実施例54)
(実施例55)
(実施例56)
(実施例57)
(実施例58)
(実施例59)
(実施例60)
(実施例61)
(実施例62)
(実施例63)
(実施例64)
すなわち、凸部サイズと凸部ピッチPの比率によって剛性効果が決定される。
また、凸部11の直径が小さいほど最大撓み量の最小値は低くなり、剛性効果が向上する。
(実施例65)
(実施例66)
(実施例67)
実施例16の薄板2において、±45°千鳥配列する凸部11の頂面部12とベース部14とをつなぐ接続面13のベース部14との接続部を直径5mmの円、接続面13を傾斜角60°の斜面とし、凸部11の頂面部12の直径は4.36mmとなる。
(実施例68)
正方配列と千鳥配列のどちらにおいても、凸部11の頂面部12とベース部14をつなぐ接続面13が斜面でも円筒形でも撓み量はほぼ同じであり、同等の剛性が得られる。
凸部11を有する薄板2の成形例として、実施例1のプリプレグ積層体を加熱プレスする方法があるが、凸部11の頂面部12とベース部14の接続面13を円筒形から斜面とすることで、プリプレグ積層体がプレスによって延伸する割合が減少したため、成形性は向上する。
なお、十分な接着面積を確保するため、斜面の傾斜角は45°以上が望ましい。
(実施例69)
(実施例70)
(実施例71)
(実施例72)
(実施例73)
(実施例74)
実施例7の正方配列が最も剛性が高く、P1が8〜12mmの範囲においても優れた剛性が得られる。
長方配列では、凸部11一個分含む等しい大きさの長方形に分割したときの長方形の長辺および短辺が、凸部11のサイズの1.6倍以上2.4倍以下であり、さらに、短辺と長辺の比率が1倍以上1.25以下であることが望ましい。
2・・・・・薄板
3・・・・・接着剤
4・・・・・樹脂構造体
5・・・・・接合部
6・・・・・繊維強化複合材料構造体
7・・・・・複合材料成形体
8・・・・・薄板用の下型
9・・・・・凸部用の突起
10・・・・凸条用の突起
11・・・・凸部
12・・・・頂面部
13・・・・接続面
14・・・・ベース部
15・・・・凸条
16・・・・凸条の上面
17・・・・凸条の側面
18・・・・先端部
19・・・・窪み
20・・・・凸条の先端
21・・・・凸条の窪み
P・・・・・凸部のピッチ
A・・・・・繊維0°積層方向
B・・・・・繊維90°積層方向
Y・・・・・支持台
Z・・・・・集中荷重
P1・・・・長方配列における凸部ピッチ1
P2・・・・長方配列における凸部ピッチ2
W1・・・・凸部のサイズ
W2・・・・凸条のサイズ
G1・・・・・第1凸部の中心軸(第1凸部の重心の位置)
G2・・・・・第2凸部の中心軸(第2凸部の重心の位置)
H・・・・・凸部の高さ
S・・・・・凸部の頂面部の面積
γ・・・・・ベース部と接続面とのなす角度
Claims (13)
- 第一面と、頂面を有するとともに前記第一面上に突出し規則的に配置された複数の凸部とを有する薄板と;第二面を有し、前記第二面で前記頂面と接合されている表面材と;を備えた繊維強化複合材料構造体と、
前記薄板の端部と前記表面材の端部との間に形成される空間に充填された接合部と、前記接合部によって前記繊維強化複合材料構造体と接合される樹脂構造体と、
を備え、
前記第一面上に突出し、
前記複数の凸部を囲むように連続して配置される凸条をさらに備え、
前記凸条と、前記薄板の前記端部と、前記表面材の前記端部とで囲まれる空間に、前記接合部が充填されている
複合材料成形体。 - 前記複数の凸部のうち一つの凸部において、前記凸部の頂面の形状及び前記凸部と前記第一面との境界線で囲まれる第1領域の形状が、
正方形、長方形、菱形、三角形、五角形、六角形、円形、楕円形、丸角正方形、丸角長方形、丸角菱形、丸角三角形、丸角五角形、及び丸角六角形から選択される少なくとも1種である
請求項1に記載の複合材料成形体。 - 前記複数の凸部は、一つの第1凸部と、前記第1凸部に隣り合う第2凸部とを有し、
前記第一面と垂直な方向における前記第1凸部の中心軸と、前記第2凸部の中心軸との間隔によって凸部ピッチが規定され、
前記凸部ピッチが前記第1領域の最小径の1.6〜2.4倍である、
請求項1又は2に記載の複合材料成形体。 - 前記複数の凸部が規則的に設けられた第2領域において、前記第2領域の面積がαで定義され、前記複数の凸部の前記頂面の面積の合計がβで定義され、比β/αが5%以上40%未満である
請求項1〜3のいずれか一項に記載の複合材料成形体。 - 前記複数の凸部のうち一つの凸部において、前記凸部の頂面の面積が前記薄板の板厚の2乗の5倍以上〜500倍未満である、
請求項1〜4のいずれか一項に記載の複合材料成形体。 - 前記複数の凸部の高さが前記薄板の板厚の0.5倍以上10倍未満である
請求項1〜5のいずれか一項に記載の複合材料成形体。 - 前記薄板は強化繊維を含み、
前記複数の凸部の配列が、
前記強化繊維における繊維の長さ方向に対して0°および90°方向に配列する正方配列ならびに長方配列、または前記複数の凸部の配列方向が前記繊維の長さ方向に対して角度をなす千鳥配列から選択される少なくとも1種の配列を含む、
請求項1〜6のいずれか一項に記載の複合材料成形体。 - 前記複数の凸部の各々において、前記頂面に平行な方向の断面における最小値フェレ径が、前記薄板の板厚の3倍以上30倍未満である
請求項1〜7のいずれか一項に記載の複合材料成形体。 - 前記複数の凸部の各々の先端部に凹状の窪みを有する、
請求項1〜8のいずれか一項に記載の複合材料成形体。 - 前記繊維強化複合材料構造体と前記樹脂構造体との接合界面に設けられた接着剤層を有する
請求項1〜9のいずれか一項に記載の複合材料成形体。 - 前記樹脂構造体が熱可塑性樹脂を含む
請求項1〜10のいずれか一項に記載の複合材料成形体。 - 前記樹脂構造体がさらにガラス繊維を含む
請求項11に記載の複合材料成形体。 - 請求項1〜12のいずれか一項に記載の複合材料成形体の製造方法であって、
強化繊維と熱硬化性樹脂組成物とを含むプリプレグ積層体を準備し、
突起または窪みを有する型を用いて前記プリプレグ積層体を加熱加圧して、複数の凸部を有する薄板を作製し、
前記薄板の前記凸部の頂面に表面材を接合することで繊維強化複合材料構造体を作製し、
樹脂材料を前記薄板と前記表面材との間に注入射出して、前記樹脂材料を含む樹脂構造体と前記繊維強化複合材料構造体とを接合する
複合材料成形体の製造方法。
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CN106696288A (zh) | 2017-05-24 |
JP2015013484A (ja) | 2015-01-22 |
JP6028777B2 (ja) | 2016-11-16 |
US10265928B2 (en) | 2019-04-23 |
US20150183183A1 (en) | 2015-07-02 |
WO2014014051A1 (ja) | 2014-01-23 |
CN104470715B (zh) | 2017-02-22 |
TW201408463A (zh) | 2014-03-01 |
CN104470715A (zh) | 2015-03-25 |
KR20150024892A (ko) | 2015-03-09 |
KR101850194B1 (ko) | 2018-04-18 |
JPWO2014014051A1 (ja) | 2016-07-07 |
CN106696288B (zh) | 2019-06-04 |
TWI556937B (zh) | 2016-11-11 |
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