JP6036844B2 - プリプレグ、繊維強化複合材料および繊維強化複合材料の製造方法 - Google Patents
プリプレグ、繊維強化複合材料および繊維強化複合材料の製造方法 Download PDFInfo
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- JP6036844B2 JP6036844B2 JP2014549004A JP2014549004A JP6036844B2 JP 6036844 B2 JP6036844 B2 JP 6036844B2 JP 2014549004 A JP2014549004 A JP 2014549004A JP 2014549004 A JP2014549004 A JP 2014549004A JP 6036844 B2 JP6036844 B2 JP 6036844B2
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Description
(1)100≦ti≦2000
(2)ti<t20≦350
式中、ti=t1+t2(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t2は、120℃にてプリプレグが30%減衰(超音波非破壊検査(NDI)にて測定)に達するまでの時間(分)であり、
t20=t1+t3(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t3は、120℃にてプリプレグが硬化度20%(示差走査熱量計(DSC)にて測定)に達するまでの時間(分)であり、熱硬化性樹脂は、コンソリデーションの時間tiを維持しつつt20を短縮させるための促進剤を含む。熱硬化性樹脂は、120℃における粘度範囲が120ポアズ〜300ポアズであることが好ましい。プリプレグは、プリプレグの表面に局在する熱可塑性粒子をさらに含んでもよい。プリプレグの含浸率は、約20%〜約95%であることが好ましい。プリプレグは、以下の条件式(1)および(2)を満たすことが好ましい。
100≦ti≦2000
80≦t20≦150
ここで、ti=t1+t2(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t2は、120℃にてプリプレグが30%減衰(超音波非破壊検査(NDI)にて測定)に達するまでの時間(分)であり、
t20=t1+t3(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t3は、120℃にてプリプレグが硬化度20%(示差走査熱量計(DSC)にて測定)に達するまでの時間(分)である。
コンソリデーション(Ti)の定義
炭素繊維
・トレカ(登録商標)T800S−24K−10E(東レ株式会社製炭素繊維:繊維フィラメント数24,000、引張強度5.9GPa、引張弾性率2.90GPa、引張伸度2.0%)
エポキシ樹脂
・ビスフェノールA型エポキシ樹脂、アラルダイト(登録商標)LY1556(ハンツマン・アドバンスト・マテリアルズ社製)
・ビスフェノールA型エポキシ樹脂、EPON(登録商標)825(モメンティブ・スペシャルティー・ケミカルズ社製)
・テトラグリシジルジアミノジフェニルメタン、アラルダイト(登録商標)MY9655(EEW:126g/eq、ハンツマン・アドバンスト・マテリアルズ社製)
熱可塑性樹脂
・末端水酸基ポリエーテルスルホン、スミカエクセル(登録商標)PES5003P(住友化学株式会社製)
硬化剤
・4,4’−ジアミノジフェニルスルホン、Aradur(登録商標)9664−1(ハンツマン・アドバンスト・マテリアルズ社製)
促進剤
DCMU(3−(3,4−ジクロロフェニル)−1,1−ジメチル尿素)(シグマ・アルドリッチ・ケミカル社製)
p−トルエンスルホン酸エチル(シグマ・アルドリッチ・ケミカル社製)98%
4−tert−ブチルカテコール(シグマ・アルドリッチ・ケミカル社製)97%
ブチルヒドロキシアニソール(シグマ・アルドリッチ・ケミカル社製)
SAN−AID SI−150(三新化学工業株式会社製)
熱可塑性樹脂粒子
・TN微粒子(東レ株式会社製)
熱硬化性樹脂は、動的粘弾性測定装置(ARES、ティー・エイ・インスツルメンツ社製)により、パラレルプレートを用い、歪み100%、周波数0.5Hz、プレート間隔1mmにて、2℃/分の速度で50℃から170℃まで単純昇温しながら測定した。
(2)熱硬化性樹脂の硬化率測定
DSC硬化度(%)=[(H0−H1)×100/H0]
(3)熱硬化性樹脂組成物の流れおよびゲル化時間
(4)プリプレグ中の熱硬化性樹脂組成物の含浸率の測定
(5)繊維強化複合材料のボイド率測定
13重量部のPES5003Pを、ミキサー中の60重量部のアラルダイト(登録商標)MY9655および20重量部のEPON(登録商標)825に溶解させて混合物を得た。この混合物に20重量部のTN(登録商標)熱可塑性樹脂粒子を加えて均一に分散させた後、硬化剤として45重量部のARADUR(登録商標)9664−1を混合物に加えて熱硬化性樹脂組成物を得た。促進剤は、表1に記載のとおり様々な量で混合物に加えた。
促進剤を使用しなかったことを除き実施例1と同様の方法でプリプレグを作製した。このプリプレグを12層積層してFRCを作製し、真空容器に入れて真空度3Kpaにて周囲温度で1時間脱気した。脱気完了後、プリプレグを1.7℃/分の速度で周囲温度から120℃まで加熱して、120℃で60分間保持した。完全コンソリデーションに達するまでの時間ti、ならびに熱硬化性樹脂組成物およびプリプレグの20%硬化に達するまでの時間T20を測定し、表1に示した。熱硬化性樹脂については粘度も測定し、50℃における粘度および最低粘度を表1に記載する。最終硬化を176℃で120分間実施した後にFRC中の熱硬化性樹脂のボイド率を測定した。結果を表1に示す。
実施例1と同様の方法でプリプレグを作製した。このプリプレグを12層積層してFRCを作製し、真空容器に入れて真空度3Kpaにて周囲温度で1時間脱気した。脱気完了後、プリプレグを1.7℃/分の速度で周囲温度から120℃まで加熱して、120℃で60分間保持した。完全コンソリデーションに達するまでの時間ti、ならびに熱硬化性樹脂組成物およびプリプレグの20%硬化に達するまでの時間T20を測定し、表1に示した。熱硬化性樹脂については粘度も測定し、50℃における粘度および最低粘度を表1に記載する。最終硬化を176℃で120分間実施した後にFRC中の熱硬化性樹脂のボイド率を測定した。結果を表1に示す。
実施例10のローラー温度を60℃とし、実施例11のローラー温度を120℃、ローラー圧力を0.14MPaとした以外は、実施例2と同様の方法でプリプレグを製造した。
実施例12の樹脂フィルムの目付けを44.7g/m2とし、実施例13ではローラー圧力を0.1MPa、樹脂フィルムの目付けを58.22g/m2とし、ローラー温度を120℃とした以外は、実施例2と同様の方法でプリプレグを製造した。プリプレグは実施例2と同様に硬化させた。結果を表1に示す。
実施例2で得た熱硬化性樹脂組成物をナイフコーターで離型紙に塗布して、68.8g/m2の樹脂フィルムを1枚作製した。次に、作製したこの樹脂フィルムのシートを、T800H−6K−40B製の平織物の片面に積層し、ローラー温度120℃、ローラー圧力0.1MPaで樹脂を含浸させて、炭素繊維の単位面積重量が190g/m2でマトリックス樹脂の重量分率が42%の一方向プリプレグを得た。得られた平織物プリプレグを用いてプリプレグ中のエポキシ樹脂組成物含有率を測定したところ、結果は42%であった。繊維強化複合材料の衝撃後圧縮強度測定とボイド率を測定した結果、それぞれ286MPa、0.5%であった。
実施例2で得た熱硬化性樹脂組成物を作製し、ナイフコーターで離型紙に塗布して137g/m2の樹脂フィルムを1枚作製する。次に、作製したこの樹脂フィルムのシートを、T800H−6K−40B製の平織物の片面に積層し、ローラー温度120℃、ローラー圧力0.1MPaで樹脂を含浸させて、炭素繊維の単位面積重量が190g/m2でマトリックス樹脂の重量分率が42%の一方向プリプレグを得る。得られた平織物プリプレグを用いてプリプレグ中のエポキシ樹脂組成物含有率を測定すると、結果は42%である。
実施例2で得た熱硬化性樹脂組成物を作製し、ナイフコーターで離型紙に塗布して68.8g/m2の樹脂フィルムを1枚作製する。次に、作製したこの樹脂フィルムのシートを、T700S−12K製の平織物の両面に積層し、ローラー温度120℃、ローラー圧力0.1MPaで樹脂を含浸させて、炭素繊維の単位面積重量が190g/m2でマトリックス樹脂の重量分率が42%の一方向プリプレグを得る。得られた平織物プリプレグを用いてプリプレグ中のエポキシ樹脂組成物含有率を測定する。
Claims (16)
- 熱硬化性樹脂および熱硬化性樹脂中の強化繊維からなるプリプレグであって、真空バッグのみの条件下で硬化させた際に以下の条件式(1)および(2)を満たすプリプレグ:
(1)100≦ti≦2000
(2)ti<t20≦350
式中、ti=t1+t2(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t2は、120℃にてプリプレグが30%減衰(超音波非破壊検査(NDI)にて測定)に達するまでの時間(分)であり、
t20=t1+t3(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t3は、120℃にてプリプレグが硬化度20%(示差走査熱量計(DSC)にて測定)に達するまでの時間(分)であり、熱硬化性樹脂は、コンソリデーションの時間tiを維持しつつt20を短縮させるための促進剤を含む。 - プリプレグの表面に局在する熱可塑性粒子をさらに含む、請求項1に記載のプリプレグ。
- プリプレグの含浸率が約20%〜約95%である、請求項1に記載のプリプレグ。
- 以下の条件式(1)および(2)を満たす、請求項1に記載のプリプレグ:
(1)100≦ti≦2000
(2)80≦t20≦150。 - 促進剤が、フェノール基および/またはスルホン酸エステル基を含む、請求項1に記載のプリプレグ。
- 促進剤の量が、熱硬化性樹脂100重量部当たり約0.5〜約10重量部である、請求項1に記載のプリプレグ。
- プリプレグが、スルホン酸基を含む成分からなる、請求項1に記載のプリプレグ。
- プリプレグが、ピロカテコール基を含む成分からなる、請求項1に記載のプリプレグ。
- プリプレグが、トシル基を含む成分からなる、請求項1に記載のプリプレグ。
- プリプレグが、芳香族スルホニウム塩を含む成分からなる、請求項1に記載のプリプレグ。
- 熱硬化性樹脂の180℃で2時間硬化させた際のTgが180℃以上である、請求項1に記載のプリプレグ。
- プリプレグを180℃で2時間硬化させた際に促進剤によって熱硬化性樹脂のTgが180℃未満に下がることがない、請求項1に記載のプリプレグ。
- 熱硬化性樹脂からなるプリプレグの処理方法であって、
プリプレグを真空バギングしてオーブン内で硬化させることによりコンソリデーション時間を決定すること、および
プリプレグの減衰損失を測定し、減衰損失が30%に達した時の時間を記録し、熱硬化性樹脂の硬化率が20%に達した時の時間を測定することを含む方法。 - プリプレグを真空バッグのみの条件下で硬化させた際に、プリプレグが以下の条件式(1)および(2)を満たす、請求項13に記載の方法:
(1)100<ti<2000
(2)ti<t20<350
ここで、熱硬化性樹脂は、コンソリデーションの時間tiを維持しつつt20を短縮させるための促進剤を含み、
式中、ti=t1+t2(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t2は、120℃にてプリプレグが30%減衰(超音波非破壊検査(NDI)にて測定)に達するまでの時間(分)であり、t20=t1+t3(分)であり、t1は、20℃から最初の保持温度120℃までの時間(分)であり、t3は、120℃にてプリプレグが硬化度20%(示差走査熱量計(DSC)にて測定)に達するまでの時間(分)であり、熱硬化性樹脂は、コンソリデーションの時間tiを維持しつつt20を短縮させるための促進剤を含む。 - 以下の条件式(1)および(2)を満たす、請求項14に記載の方法:
(1)100<ti<2000
(2)80<t20<150。 - 請求項1に記載のプリプレグを熱硬化して作製する硬化繊維強化複合材料。
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-
2012
- 2012-12-26 US US14/367,267 patent/US9963586B2/en active Active
- 2012-12-26 KR KR1020147019750A patent/KR101996111B1/ko active IP Right Grant
- 2012-12-26 EP EP12860178.8A patent/EP2794272B1/en active Active
- 2012-12-26 JP JP2014549004A patent/JP6036844B2/ja active Active
- 2012-12-26 CN CN201280063920.7A patent/CN104023979B/zh active Active
- 2012-12-26 RU RU2014130202A patent/RU2014130202A/ru not_active Application Discontinuation
- 2012-12-26 BR BR112014015544A patent/BR112014015544A2/pt not_active IP Right Cessation
- 2012-12-26 WO PCT/US2012/071641 patent/WO2013096968A2/en active Application Filing
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WO2013096968A2 (en) | 2013-06-27 |
KR101996111B1 (ko) | 2019-07-03 |
EP2794272B1 (en) | 2019-02-27 |
WO2013096968A9 (en) | 2014-05-08 |
RU2014130202A (ru) | 2016-02-20 |
US20140309336A1 (en) | 2014-10-16 |
CN104023979B (zh) | 2015-08-05 |
EP2794272A4 (en) | 2016-07-06 |
KR20140111292A (ko) | 2014-09-18 |
US9963586B2 (en) | 2018-05-08 |
CA2859531A1 (en) | 2013-06-27 |
CN104023979A (zh) | 2014-09-03 |
BR112014015544A2 (pt) | 2017-08-22 |
EP2794272A2 (en) | 2014-10-29 |
JP2015515502A (ja) | 2015-05-28 |
WO2013096968A3 (en) | 2015-02-05 |
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