JP6122375B2 - Porous structure comprising thermoplastic carbon fiber resin substrate and method for producing the same - Google Patents

Description

  The present invention relates to a porous structure made of a composite material containing a thermoplastic resin and carbon fiber, and more specifically, made of a composite material, lightweight and highly rigid, capable of hot bending, a filter, a package, and heat insulation. The present invention relates to a porous structure suitable for materials, vibration-proof materials, and sound-proof materials.

  Conventionally, a porous body made of a metal material has been used for applications such as a filter, a package, a heat insulating material, a vibration isolating material, and a sound insulating material. For example, Patent Documents 1 to 3 describe using a metal wire mesh filter or punching metal in order to remove dust in the exhaust gas of a car. However, a metal material generally has a large specific gravity, and development of a lighter porous body has been demanded in applications such as automobiles that require severe improvement in fuel efficiency.

  In addition, a dust removal filter made of a metal material may have a reduced dust removal performance due to metal fatigue or exhaust gas corrosion, and it has been difficult to maintain environmental performance over a long period of time.

  On the other hand, cited document 4 describes using carbon fiber as a weaving thread in a large bag filter attached to a dust collector or a dust filter. However, the carbon fiber itself is expensive, and when it is used as a woven yarn, it is very difficult to suppress the manufacturing cost because it costs more to fabricate due to the difficulty of knitting.

JP 2004-105954 A JP 2002-336627 A JP 2002-097927 A JP 2011-045848 A

  The present invention has been made in view of the problems of the prior art, and an object thereof is to provide a porous structure made of a composite material having high rigidity, light weight, and excellent workability. The present invention also provides a method for producing a porous structure composed of such a composite material, and a porous molded body obtained by molding the porous structure.

In order to solve the above problems, the porous structure according to the present invention has any one of the following configurations (1) to (10).
(1) A porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end surface to the other end surface, A porous structure characterized in that, on the end face and the other end face, the total opening area of the plurality of through holes is 10 to 90% of the total area of the end face.
(2) The composite material contains 5 to 60% by weight of carbon fiber, and the ratio of carbon fiber having a fiber length of 0.05 to 1.0 mm is 70% by weight or more with respect to the entire carbon fiber. The porous structure of (1) above.
(3) The composite material is composed of a first thermoplastic resin, a second thermoplastic resin, and carbon fiber, and the composite material is disposed in the sea phase composed of the second thermoplastic resin. The porous structure according to (1) or (2) above, wherein the island phase composed of the thermoplastic resin is dispersed.
(4) The porous structure according to any one of (1) to (3), wherein the shape of the opening of the through hole is a circle, an ellipse, or a polygon.
(5) The porous structure according to any one of (1) to (4), wherein the longest diameter of the opening of the through hole is 0.01 mm to 100 mm.
(6) The porous structure according to any one of (1) to (5) above, wherein the base material has a thickness of 0.05 mm to 100 mm.
(7) The porous structure according to any one of (1) to (6), wherein openings of the plurality of through holes are arranged at substantially equal intervals at intervals of 0.02 mm to 200 mm on the one end surface. .
(8) The porous structure according to any one of (1) to (7), wherein the porous structure has a multilayer structure including a layer made of the substrate.
(9) The porous structure according to any one of the above (1) to (8), which is used as a filter, a package, a heat insulating material, a vibration isolating material, or a sound insulating material.
(10) The porous structure according to any one of (1) to (9), which is used for an aircraft, a rocket, an artificial satellite, an automobile, a motorcycle, a railway train, or a house.
Moreover, the porous molded body according to the present invention has the following configuration (11).
(11) A porous molded body obtained by hot press molding or hot bending forming the porous structure according to any one of (1) to (10) above.
Moreover, the manufacturing method of the porous structure which concerns on this invention has the structure of following (12) or (13).
(12) The method for producing a porous structure according to any one of (1) to (10), wherein the through hole is formed using any one of a metal mold, a laser beam, and a jet water flow. A method for producing a porous structure.
(13) The method for producing a porous structure according to (12) above, wherein the core component is made of carbon fiber and the sheath component is made of a first thermoplastic resin, and the pellet has a core-sheath structure at a predetermined temperature. The composite material is melted with a second thermoplastic resin having a viscosity higher than that of the first thermoplastic resin, and the molten pellets and the second thermoplastic resin are kneaded at the predetermined temperature. further comprising a step of producing, when the melting point of the second thermoplastic resin and T _2, the pellets and the second thermoplastic resin is kneaded in a temperature range of T _{2 +} 10~T _{2 + 70} ℃ A method for producing a porous structure.

  According to the present invention, a porous structure made of a composite material that is lightweight and excellent in rigidity can be obtained. Further, since the composite material is basically made of a thermoplastic resin, heat treatment is easy, and the composite material can be processed into a complicated shape while maintaining the porous structure. Moreover, the manufacturing method which can be shape | molded by using the existing press equipment can be provided.

It is a schematic perspective view of the porous structure which concerns on one embodiment of this invention. It is a schematic perspective view of a base material. It is sectional drawing along the AA line of FIG. It is a schematic cross section which shows the structure of a composite material. It is a schematic side view which illustrates the structure of a punching machine.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

  A porous structure according to the present invention is a porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end face to the other end face. Then, the total opening area of the plurality of through holes is 10 to 90% of the total area of the end faces on the one end face and the other end face.

  1 and 2 are diagrams for explaining the structure of the porous structure. FIG. 1 is a schematic perspective view showing a porous structure according to an embodiment of the present invention, and particularly shows an example of a porous structure having a single-layer structure consisting essentially of a base material. FIG. 2 is a schematic perspective view showing a state of the base material before the through hole is formed. In FIG. 1, a substantially sheet-like porous structure 1 has a base material 2 made of a composite material including a thermoplastic resin and carbon fibers, and the base material 2 has one end face 6a to the other end face 6b. A plurality of through holes 3 penetrating therethrough are formed. The porous structure 1 is obtained, for example, by forming a plurality of through holes 3 in a substantially sheet-like base material 2 shown in FIG. Since the composite material including the thermoplastic resin and the carbon fiber is excellent in rigidity and toughness, it is difficult to cause breakage such as cracks, and even in a state where a plurality of through holes 3 are formed as shown in FIG. Exhibits excellent durability. Further, both the thermoplastic resin and the carbon fiber have a smaller specific gravity than the conventional metal material, and the porous structure 1 provided with the through holes is extremely light.

  FIG. 3 is a schematic cross-sectional view taken along the line AA in FIG. In FIG. 3, the short carbon fiber 5 is mix | blended in the base material 2, and the thermoplastic resin 4 is filled between carbon fibers. According to such a configuration, since the rigidity of the base material 2 is isotropically enhanced by the carbon fibers 5, the base material 2 having both high rigidity and excellent toughness can be obtained. As a result, even when the through hole 3 is formed as shown in FIGS. 1 and 3, the porous structure 1 can exhibit excellent durability.

  Examples of the thermoplastic resin include polyolefin (for example, polyethylene (PE), polypropylene (PP), polybutylene, polystyrene, etc.), polyamide (for example, nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, aromatic nylon). Etc.), polyimide, polyamideimide, polycarbonate, polyester (for example, polyethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate), polyphenylene sulfide (PPS), polysulfoxide, polytetrafluoroethylene, acrylonitrile butadiene styrene copolymer (ABS) , Polyacetal, polyether, polyether-ether-ketone, polyphenylene oxide and the like. Moreover, the derivative | guide_body of the said thermoplastic resin, the copolymer of the said thermoplastic resin, and also a mixture thereof may be sufficient.

  Among the above thermoplastic resins, in particular, nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, aromatic nylon, polyethylene terephthalate, polybutylene terephthalate, polyphenylene sulfide (PPS), polycarbonate, polyethylene, polypropylene, acrylonitrile butadiene Styrene copolymer (ABS) is preferably used.

  In the one end surface and the other end surface, the total opening area of the through holes is 5 to 95% of the total area of the end surface. That is, the total opening area of the through holes in one end face is 5 to 95% of the total area of one end face, and the total opening area of the through holes in the other end face is 5 to 95 of the total area of the other end face. %. Hereinafter, the ratio of the total opening area of the through holes to the total area of the end faces (the total opening area of the through holes / the total area of the end faces) may be simply referred to as an opening ratio (%). In the porous structure of the present invention, from the viewpoint of balance between weight and strength, the opening ratio is preferably 10 to 90%, more preferably 20 to 80%, and further preferably 30 to 70%.

  In the present invention, the through-hole means a hole formed so as to penetrate substantially linearly from one end surface to the other end surface, and adjacent bubbles communicate with each other in a porous body such as a sponge. This is different from a so-called open cell structure in which one end face communicates with the other end face. However, the porous structure of the present invention may further have an open-cell structure. For example, the porous structure of the present invention can be provided by further providing a plurality of substantially linear through holes in a porous material made of a composite material. It is also possible to get a body.

  The carbon fiber content of the composite material is preferably 5 to 60% by weight, more preferably 10 to 35% by weight, and still more preferably 15 to 25% by weight with respect to the entire composite material.

  Moreover, it is preferable that the composite material contains short fibers of carbon fibers. Specifically, in the composite material, it is preferable that carbon fibers having a fiber length of 0.05 to 1.0 mm are present in an amount of 50% by weight or more based on the total carbon fiber, and the fiber length is 0.05 to 1. More preferably, 0 mm of carbon fiber is present in an amount of 70% by weight or more based on the entire carbon fiber, and carbon fiber having a fiber length of 0.1 to 0.5 mm is present in an amount of 70% by weight or more based on the entire carbon fiber. More preferably, it is particularly preferable that the carbon fiber having a fiber length of 0.15 to 0.4 mm is present in an amount of 70% by weight or more based on the entire carbon fiber. Note that the composite material may further include continuous carbon fibers (long fibers of carbon fibers), or may further include fibers other than carbon fibers.

  The composite material is composed of a first thermoplastic resin, a second thermoplastic resin, and carbon fiber, and an island phase composed of the first thermoplastic resin in a sea phase composed of the second thermoplastic resin. It is preferable to have a structure in which is dispersed. Moreover, it is preferable that the 2nd thermoplastic resin has a viscosity higher than a 1st thermoplastic resin. As an example of a composite material having such a sea-island structure, a carbon fiber composite material that has not been disclosed at the time of filing the present application but described in International Application PCT / JP2013 / 064655 can be given.

  FIG. 4 is a schematic cross-sectional view showing a cross section of a composite material having a sea-island structure. As shown in FIG. 4, in the composite material 70, the island phase composed of the first thermoplastic resin 71 having a low viscosity is dispersed in the sea phase composed of the second thermoplastic resin 72 having a high viscosity. The carbon fiber 5 and the island phase (thermoplastic resin 71) are uniformly dispersed in the composite material 70. The carbon fiber 5 is mainly present in the island phase composed of the first thermoplastic resin 71 having a low viscosity and high affinity with the carbon fiber, thereby ensuring adhesion between the carbon fiber and the resin. Has been.

  According to the composite material having such a sea-island structure, the carbon fiber and the resin are wrapped with the first thermoplastic resin having a relatively low viscosity, thereby ensuring the affinity between the carbon fiber and the resin. By covering the first thermoplastic resin with the second thermoplastic resin having a high viscosity, the carbon fiber and the island phase can be uniformly dispersed in the sea phase, resulting from the uneven distribution of the carbon fiber and the thermoplastic resin. Problems during molding (for example, springback and voids) are prevented in advance. Therefore, by using the composite material, the degree of freedom of molding is greatly improved, and various molding processes can be performed.

  When the composite material has the sea-island structure, the melting point of the first thermoplastic resin is preferably 100 to 370 ° C. Moreover, it is preferable that melting | fusing point of a 2nd thermoplastic resin is 100-370 degreeC.

  Further, the first thermoplastic resin and the second thermoplastic resin may have the same or different resin components. For example, among two types of resins having the same components but different polymerization degrees and viscosities, a resin having a relatively low viscosity is designated as a first thermoplastic resin, and a resin having a relatively high viscosity is designated as a second heat. It can also be used as a plastic resin.

  Furthermore, the refractive index of the first thermoplastic resin is preferably different from the refractive index of the second thermoplastic resin.

  When the composite material has the sea-island structure, from the viewpoint of securing the affinity between the carbon fiber and the resin, the proportion of the carbon fiber present in the island phase is preferably 50% by weight with respect to the entire carbon fiber, It is more preferably 70% by weight or more, and further preferably 90% by weight or more.

  The average diameter of the island phase is preferably 10 nm to 500 μm. In addition, the average diameter of an island phase refers to the average value of the diameter when each island phase is converted into a perfect circle of the same area in the cross section of the carbon fiber composite material.

  The shape of the opening of the through hole is preferably a circle, an ellipse, or a polygon, and is preferably a free curve. In addition, from the viewpoint of ease of processing, a circular shape or a quadrangular shape is more preferable.

  The longest diameter of the opening of the through hole is preferably 0.01 to 100 mm, more preferably 0.05 to 50 mm, and further preferably 0.1 to 20 mm.

  In the one end face and the other end face, the openings of the plurality of through holes are preferably arranged at substantially equal intervals with an interval of 0.02 to 200 mm. That is, it is preferable that the openings are arranged at substantially equal intervals on one end face, and the openings are also arranged at substantially equal intervals on the other end face. Here, the interval between the openings refers to the distance from the center of one opening to the center of the adjacent opening. By arranging the openings at substantially equal intervals, it is possible to minimize the unevenness in strength, and mechanical properties such as rigidity and flexural modulus are maintained at a high level. In addition, it is more preferable that the space | interval of an opening part is 0.05-100 mm, and it is further more preferable that it is 0.2-40 mm.

  The flexural modulus of the substrate is preferably 5 to 500 GPa, more preferably 10 to 300 GPa, and further preferably 10 to 100 GPa. In addition, as a measuring method of a bending elastic modulus, the method based on JISK7074 (1988) and the method based on JISK7171 (2008) can be used, for example.

  Moreover, it is preferable that the thickness of a base material is 0.05-100 mm, It is more preferable that it is 0.1-50 mm, It is further more preferable that it is 0.3-20 mm.

  Although the magnitude | size of a base material is not specifically limited, From the point of workability, a 100-1000 mm square size and about 0.2-10 mm thickness are normally used.

  The porous structure may have a single-layer structure consisting essentially only of a base material, or may have a multilayer structure including a layer consisting of a base material. For example, it may have a sandwich structure in which a surface material is laminated on one side of a base material layer made of a composite material and a backing material is laminated on the other side of the base material layer, or a pair of base material layers It may have a sandwich structure in which a core material layer is provided therebetween. Or it is also possible to employ | adopt the laminated structure on which the base material layer and the other layer were laminated | stacked alternately. Examples of the material of the layer other than the base material layer include, for example, thermoplastic resins, thermosetting resins, metals, ceramics, wood, glass, or combinations thereof. It is not limited. In addition, a layer made of a foamed resin (which may be either a thermoplastic resin or a thermosetting resin) may be provided in the porous structure as a layer other than the base material layer, and the structure of the foamed resin layer is a closed cell structure. Any of open cell structures may be used.

  The porous structure according to the present invention can be suitably used as a filter, a packing material, a heat insulating material, a vibration isolating material, or a sound insulating material. A composite material including a thermoplastic resin and carbon fiber is superior in vibration proofing, soundproofing, and heat insulating properties as compared with a conventional metal material. In addition, since the composite material is very lightweight, it has excellent transportability. For example, when it is used as a material for vehicle parts, an increase in fuel consumption can be minimized. Furthermore, since the composite material does not contain a metal and there is no risk of corrosion or metal fatigue, the use of the porous structure of the present invention as a filter makes it possible to maintain high environmental performance for a long period of time.

  In addition, since the porous structure of the present invention uses a base material made of a composite material including a thermoplastic resin and carbon fiber, it can be flexibly heat-molded, and is vibration-proof and heat-insulating after molding. Excellent characteristics such as are maintained. Therefore, the porous structure of the present invention can be suitably used for applications that require a high level of durability such as vibration resistance and impact resistance, and applications that require processing into complex shapes. Examples of such applications include aircraft, rockets, artificial satellites, automobiles, motorcycles, railroad trains, and houses.

  The present invention also provides a porous molded body obtained by molding the porous structure. As described above, since the thermoplastic composite material is used for the porous structure of the present invention, it is possible to perform thermoforming while maintaining the porous structure, and not only a simple flat plate shape but also a complicated curved surface. It can be formed into a three-dimensional shape. Examples of the forming method include hot press forming and hot bending forming, and a plurality of forming methods can be combined. Note that, during the molding process, the through holes formed in the porous structure may be deformed by heat or pressure.

  As a method of the above hot press molding, for example, a method of forming a porous structure by heating the porous structure to a semi-molten state and then pressing with an open mold comprising an upper mold and a lower mold Is mentioned.

  The present invention also provides a method for producing the porous structure. That is, it is a method for producing a porous structure having through holes by forming a plurality of through holes in a structure having a base material made of a composite material including a thermoplastic resin and carbon fibers. Examples of the drilling means for forming the through hole include a metal mold, a laser beam, and a jet water stream.

  Examples of the punching means (punching machine) provided with a metal mold include an apparatus described in Japanese Utility Model Laid-Open No. 61-87625. Moreover, it is also possible to carry out continuous production of the porous structure by using a press device provided with a metal mold as the punching means.

  FIG. 5 is a schematic side view showing an example of a punching machine that can be used in the production of the porous structure of the present invention, and particularly shows an example of a press apparatus provided with a metal mold. In FIG. 5, a punching machine 80 includes a metal mold composed of a lower mold 83 and an upper mold 86 opposed to each other, a press machine 88 provided with a striker 87 for pressing the upper mold 86, and a base for fixing the base material. And a table 81. The lower die 83 is fixed to the lower turret 84, and the upper die 86 is accommodated in a guide hole 90 provided in the upper turret 85 so as to be slidable in the vertical direction. Further, the table 81 is provided with a clamp 82 and a ball 89 for holding the base material, and the clamp 82 can move on the table 81 in a horizontal direction while holding the base material. Although not shown, the upper turret 85 is provided with urging means (for example, a spring) that can urge the upper mold 86 upward.

  When the through hole is formed in the base material 2, the striker 87 is moved downward by the press machine 88 with the base material 2 fixed to the clamp 82 of the table 82 as shown in FIG. The upper die 86 accommodated in the lower portion 86 is pushed downward against the pressing force of the urging means. The upper die 86 pushed down by the striker 87 punches the base material 2 in cooperation with the lower die 83 fixed to the lower turret 84, and forms a through hole 3 penetrating from the end surface 6a to the end surface 6b in the base material 2. . When the striker 87 is raised by the press 88 after punching, the upper die 86 is returned to the original position by the urging means. Further, when the base 2 is moved in the horizontal direction by the clamp 82 when the upper mold 86 is not pushed down, the base 2 moves relative to the upper mold 86 and the lower mold 83. Therefore, the porous structure of the present invention can be obtained by punching with the press machine 88 while positioning the substrate 2 using the clamp 82. In addition, it is also possible to manufacture a porous structure in which holes having different shapes and sizes are formed by using a plurality of upper molds while switching.

The method for producing a porous structure of the present invention may further include a step of producing a composite material. As a process of manufacturing a composite material, the process of manufacturing the composite material which has the above-mentioned sea island structure etc. are mentioned, for example. That is, a pellet having a core-sheath structure made of carbon fiber and having a sheath component made of a first thermoplastic resin, and a second thermoplastic resin having a viscosity higher than that of the first thermoplastic resin at a predetermined temperature. It is a step of melting and kneading the melted pellets and the second thermoplastic resin at a predetermined temperature. Here, the melting point of the second thermoplastic resin (when the second thermoplastic resin is amorphous has a glass transition point) when the a T _2, pellets and the second thermoplastic resin is T ₂ +10 It is kneaded in a temperature range of ~T ₂ + 90 ℃. The temperature at which the pellets and the second thermoplastic resin is kneaded _is preferably _{T 2 + 30~T 2 + 90 ℃} , and more preferably _{T 2 + 40~T 2 + 90 ℃} .

  At the predetermined temperature, the viscosity of the second thermoplastic resin is preferably 10 to 750 times, more preferably 20 to 500 times, and more preferably 50 to 200 times the viscosity of the first thermoplastic resin. More preferably.

  In addition, in the said predetermined temperature, it is preferable that the viscosity of a 1st thermoplastic resin is 50-500 poise, and it is more preferable that it is 100-300 poise. In addition, at the predetermined temperature, the viscosity of the second thermoplastic resin is preferably 1,000 to 10,000 poise, and more preferably 1,500 poise to 5,000 poise.

  When kneading the melted pellet and the second thermoplastic resin, it is preferable to use a uniaxial or biaxial extruder. Further, a vacuum vent is preferably provided in the latter half of the cylinder of the extruder, and a gear pump is preferably provided at the tip of the extruder.

  Moreover, when manufacturing a composite material, carbon fiber can also be added to the fuse | melted pellet and 2nd thermoplastic resin. Thereby, the content rate of the carbon fiber in a composite material can be raised, and intensity | strength can be improved. Examples of the method for adding the carbon fiber include a method for directly supplying the carbon fiber filament drawn from the carbon fiber roving to the extruder, and a method for supplying the carbon fiber cut to an appropriate length to the extruder. It is done.

  The method for producing a porous structure may further include a step of producing a substrate using a composite material. As a process of manufacturing a base material, the process of manufacturing the base material which consists of a composite material is mentioned by fuse | melting the composite material manufactured by the said manufacturing method, and shape | molding after that, for example. The base material may be molded by injection molding, or may be extrusion molding such as solidified extrusion or melt extrusion.

  Conventionally, metal plates have been used as the material for porous structures, but metal porous structures are difficult to reduce weight and are used for airplanes, cars, railway trains, rockets, etc. where improvement in fuel efficiency is important Therefore, the appearance of a lighter product was desired.

  On the other hand, when a fiber reinforced resin obtained by impregnating a reinforced fiber with a thermosetting resin is used as the material of the porous structure, a lightweight and highly rigid product can be obtained, but in the manufacturing process, the curable prepreg is frozen. Expensive equipment such as low-temperature equipment for storage underneath and high-temperature equipment for autoclaving is required, resulting in a very high manufacturing cost. Further, if the pitch interval of the drilling process is too narrow, burrs increase and delamination occurs, and it is difficult to meet a wide range of market demands.

  On the other hand, the porous structure of the present invention made of a composite material including a thermoplastic resin and carbon fiber has excellent durability while being lightweight as described above, and has high moldability, so Respond flexibly to requests. In addition, since manufacturing and molding can be performed basically using an existing apparatus for thermoplastic resin, the cost can be kept very low.

  Hereinafter, the present invention will be described in detail based on examples and comparative examples. In addition, unless otherwise indicated, the test conditions in each Example and a comparative example shall be based on Example 1 fundamentally.

(Materials used)
(A) Thermoplastic resin for the surface material A1: Nylon 6 (melting point: 225 ° C.)
A2: Nylon 66 (melting point: 255 ° C.)
A3: PP (melting point: 170 ° C.)
A4: ABS (softening point: 115 ° C.)
A5: PPS (melting point: 285 ° C.)
A6: PE (melting point: 110 ° C.)

Example 1
Using a composite material containing 70% by weight of nylon 6 and 30% by weight of carbon fiber (carbon fiber having a fiber length of 0.20 to 0.30 mm is contained by 50% by weight with respect to the entire carbon fiber) One sheet-like substrate 2 having a thickness of 1.5 mm, a width of 800 mm, and a length of 1100 mm is prepared. Using this substrate, a porous structure is manufactured by a punching machine 80 shown in FIG.
First, a sheet-like base material 2 made of a composite material including nylon 6 and carbon fiber is placed on a table 81 of a punching machine 80 and fixed with a clamp 82. Then, the striker 87 is pressed downward at a pressure of 20 MPa by the press machine 88, and the upper die 86 slidably accommodated in the upper turret 85 is pushed down. The upper die 86 has a circular cross-sectional shape of 3 mm in diameter, and the upper die 86 pushed down by the striker 87 punches the base material 2 in cooperation with the lower die 83 fixed to the lower turret 84, and from the end surface 6a. A through hole 3 that penetrates to the end face 6 b is formed in the base material 2. The shape of the opening of the through hole 3 is substantially circular, and the diameter of the opening is 3.0 mm. When the striker 87 is raised by the press 88 after punching, the upper die 86 is also returned to the original position.
Subsequently, the clamp 82 holding the base material 2 is moved 5 mm in a direction that forms an angle of 60 degrees with respect to the longitudinal direction of the base material 2 (hereinafter also simply referred to as “oblique direction”), and the base material 2 is moved. After moving relative to the upper mold 86 and the lower mold 83, a punching operation is performed to form a second through hole having a diameter of 3.0 mm in the base material 2. At this time, the distance from the axis of the second through hole to the axis of the first through hole is 5 mm, and the width between the second through hole and the first through hole is 2 mm. Thus, by repeating the punching process and the substrate moving process along the predetermined direction at equal intervals, through holes formed at equal intervals can be obtained. In this example, a sheet-like porous structure in which through holes are arranged in a staggered manner (triangular lattice shape) by punching the base material 2 at intervals of 5 mm along each of the oblique direction and the sheet longitudinal direction. Get one.
In the obtained porous structure 1, the shape of the opening of the through hole 3 is a substantially circular shape having a diameter of 3.0 mm, the distance from the center of the opening to the center of the adjacent opening is 5 mm, The width between them was 2 mm. The arrangement of the through holes 3 was a staggered arrangement, and the ratio of the total area of the openings of the through holes to the total area of the end faces, that is, the hole area ratio was 32.6%. Moreover, the weight per unit area was 1264 g / m < ² >.

(Example 2)
Using a composite material containing 80% by weight of PP and 20% by weight of carbon fiber (carbon fiber having a fiber length of 0.20 to 0.30 mm is contained by 50% by weight with respect to the entire carbon fiber) A sheet having a length of 1.0 mm, a width of 800 mm, and a length of 10 m is prepared and fixed on a punching machine table with a clamp. An upper die having a substantially circular shape with a cross-sectional diameter of 6 mm is attached to a punching machine, and punching is performed by punching the base material at intervals of 9 mm along the longitudinal direction of the sheet and the above-described oblique direction (see Example 1). A sheet-like porous structure in which the holes are arranged in a staggered manner is obtained.
In the obtained porous structure, the shape of the opening of the through hole is a substantially circular shape having a diameter of 6 mm, the distance from the center of the opening to the center of the adjacent opening is 9 mm, and the width between the holes is It was 3 mm. The arrangement of the through holes was a staggered arrangement, and the aperture ratio was 40.3%. Further, the weight per unit area was 657 g / m ² .

(Example 3)
Using a composite material containing 85% by weight of PE and 15% by weight of carbon fibers (carbon fibers having a fiber length of 0.20 to 0.30 mm are included in an amount of 50% by weight with respect to the total carbon fibers) One sheet-like base material having a width of 0.6 mm, a width of 800 mm, and a length of 1100 mm is prepared and fixed on a punching machine table with a clamp. An upper die having a substantially square shape with a cross-sectional shape of 5 mm on a side is attached to a punching machine, and a punched machine is punched at intervals of 8 mm along the sheet longitudinal direction and width direction to form a sheet shape in which through holes are arranged in a lattice shape To obtain a porous structure.
In the obtained porous structure, the shape of the opening of the through hole is a substantially square shape with a side of 5 mm, the distance from the center of the opening to the center of the adjacent opening is 8 mm, and the width between the holes is It was 3 mm. The arrangement of the through holes was a parallel arrangement (lattice shape), and the hole area ratio was 39.1%. Further, the weight per unit area was 315 g / m ² .

Example 4
Using a composite material containing 65% by weight of nylon 66 and 35% by weight of carbon fiber (carbon fiber having a fiber length of 0.20 to 0.30 mm is contained by 50% by weight with respect to the entire carbon fiber), One sheet-like base material having a thickness of 0.6 mm, a width of 800 mm, and a length of 1100 mm is prepared and fixed on a punching machine table with a clamp. A sheet shape in which through holes are arranged in a grid by attaching an upper die having a substantially square shape with a side cross section of 3 mm to a punching machine and punching the substrate at intervals of 5 mm along the longitudinal and width directions of the sheet. To obtain a porous structure.
In the obtained porous structure 1, the shape of the opening of the through hole 3 is a substantially square with a side of 3 mm, the distance from the center of the hole to the center of the adjacent hole is 5 mm, and the width between the holes is 2 mm. Met. The arrangement of the through holes was a parallel arrangement, and the opening ratio was 36%. Moreover, the weight per unit area was 499 / m < ² >.

(Example 5)
Using a composite material containing 85% by weight of ABS and 35% by weight of carbon fiber (carbon fiber having a fiber length of 0.20 to 0.30 mm is contained by 50% by weight with respect to the entire carbon fiber) One sheet-like base material having a width of 0.6 mm, a width of 800 mm, and a length of 1100 mm is prepared and fixed on a punching machine table with a clamp. An upper die having a substantially circular shape with a cross-sectional diameter of 8 mm is attached to a punching machine, and punched through the base material at intervals of 10 mm along the longitudinal direction of the sheet and the above-described oblique direction (see Example 1). A sheet-like porous structure in which the holes are arranged in a staggered manner is obtained.
In the obtained porous structure, the shape of the opening of the through hole is a substantially circular shape having a diameter of 8 mm, the distance from the center of the opening to the center of the adjacent opening is 10 mm, and the width between the holes is It was 2 mm. The arrangement of the through holes was a staggered arrangement, and the aperture ratio was 58%. Further, the weight per unit area was 277 g / m ² .

(Example 6)
Using a composite material containing 80% by weight of PPS and 20% by weight of carbon fiber (carbon fiber having a fiber length of 0.20 to 0.30 mm is contained by 50% by weight with respect to the total carbon fiber) One sheet-like base material having a width of 0.6 mm, a width of 800 mm, and a length of 1100 mm is prepared and fixed on a punching machine table with a clamp. An upper die having a substantially circular shape with a cross section of 5 mm in diameter is attached to a punching machine, and through-holes are formed radially at intervals of 8 mm to obtain a sheet-like porous structure.
In the obtained porous structure, the shape of the opening of the through hole is a substantially circular shape having a diameter of 5 mm, the distance from the center of the opening to the center of the adjacent opening is 8 mm, and the width between the holes is It was 3 mm. The arrangement of the through holes was radial, and the hole area ratio was 58%. Further, the weight per unit area was 363 g / m ² .

(Example 7)
The porous structure 1 described in Example 1 was placed in a single die having a heater and a water-cooled tube. This mold was composed of a box-shaped concave mold and a convex mold having a shape corresponding thereto, and the dimensions of the shaped part were 31.5 mm in height, 150 mm in width, and 170 mm in length. Subsequently, the mold was closed and pressurized for 5 minutes under the conditions of a mold temperature of 230 ° C. and a pressure of 15 MPa. And after cooling a metal mold | die with a water-cooled pipe and opening a metal mold | die, the taken-out hot press molded object was deburred, and the box-shaped structure which has a some through-hole was obtained.
The dimensions of the obtained structure were 31.5 mm in height, 150 mm in width, 170 mm in length, and 1.5 mm in thickness.

(Comparative Example 1)
A sheet-like porous structure was obtained in the same manner as in Example 1 except that an iron sheet having a thickness of 1.5 mm, a width of 800 mm, and a length of 1100 mm was used as a base material.
In the obtained porous structure 1, the shape of the opening of the through hole 3 is a substantially circular shape having a diameter of 3.0 mm, the distance from the center of the opening to the center of the adjacent opening is 5 mm, The width between them was 2 mm. The arrangement of the through holes 3 was a staggered arrangement, and the hole area ratio was 32.6%. The weight per unit area was 7936 g / m ² .

(Comparative Example 2)
Two surface materials were prepared using a fiber reinforced resin obtained by impregnating a liquid epoxy resin into a nonwoven fabric composed of short carbon fibers. Also, a polyurethane sheet (thickness: 20 mm, width: 750 mm, length 1000 mm) having a closed cell structure was prepared as a core material. The said surface material was laminated | stacked on both surfaces of the core material, and the epoxy resin was impregnated in the core material. And this laminated body was put into the autoclave, and it heated at 180 degreeC for several hours, the epoxy resin was hardened, and the sandwich structure was obtained.
When this sandwich structure was used as a base material and an attempt was made to form a through hole in the same manner as in Example 1 at a pressure of 80 MPa, a through hole having a diameter of 3 mm was drilled, but delamination occurred. The desired porous structure could not be obtained. Further, a bundle of carbon fibers was exposed on the end face, and it was necessary to perform deburring.

  The porous structure of the present invention can be suitably used for applications such as filters, filters, packing materials, heat insulating materials, vibration insulating materials, and sound insulating materials. In addition, the structure according to the present invention is required to be molded into a complicated curved shape while maintaining high rigidity, for example, an aircraft, a rocket, an artificial satellite, an automobile, a motorcycle, a railway train, a house, etc. Can be suitably used.

DESCRIPTION OF SYMBOLS 1 Porous structure 2 Base material 3 Hole 4 Thermoplastic resin 5 Carbon fiber 6a, 6b End surface 70 Composite material 71 1st thermoplastic resin 72 2nd thermoplastic resin 80 Punching machine 81 Table 82 Clamp 83 Lower mold 84 Lower turret 85 Upper turret 86 Upper mold 87 Striker 88 Press machine 89 Ball 90 Guide hole

Claims (12)

A porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end face to the other end face,
In the end face and another end face of said one opening total area of the plurality of through holes, Ri 10-90% der of the total area of the end face,
Said composite material has contained 5 to 60 wt% of carbon fibers, the proportion of carbon fibers having a fiber length is 0.05~1.0mm is, the Der Rukoto 70 wt% or more with respect to the total carbon fiber Characteristic porous structure. A porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end face to the other end face,
In the end face and another end face of said one opening total area of the plurality of through holes, Ri 10-90% der of the total area of the end face,
The composite material includes a first thermoplastic resin, a second thermoplastic resin, and carbon fiber, and the composite material is included in the first thermoplastic resin in a sea phase composed of the second thermoplastic resin. porous structure composed of the resin island phase is characterized Rukoto that have a structure that is dispersed. The porous structure according to claim 1 or 2 , wherein the shape of the opening of the through hole is a circle, an ellipse, or a polygon. The longest diameter of the opening portion of the through hole is 0.01Mm～100mm, porous structure according to any one of claims 1-3. The porous structure according to any one of claims 1 to 4 , wherein the substrate has a thickness of 0.05 mm to 100 mm. The porous structure according to any one of claims 1 to 5 , wherein openings of the plurality of through holes are arranged at substantially equal intervals at intervals of 0.02 mm to 200 mm on the one end surface. The porous structure according to any one of claims 1 to 6 , wherein the porous structure has a multilayer structure including a plurality of layers made of the base material. The porous structure according to any one of claims 1 to 7 , which is used as a filter, a package, a heat insulating material, a vibration isolating material, or a sound insulating material. The porous structure according to any one of claims 1 to 8 , which is used for an aircraft, a rocket, an artificial satellite, an automobile, a motorcycle, a railway train, or a house. A porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end face to the other end face, wherein the one end face and the other end face A porous molded body formed by hot pressing or hot bending a porous structure in which the total opening area of the plurality of through holes is 10 to 90% of the total area of the end surface . A porous structure having a base material made of a composite material including a thermoplastic resin and carbon fibers, and having a plurality of through holes penetrating from one end face to the other end face, wherein the one end face and the other end face In the manufacturing method of the porous structure , the total opening area of the plurality of through holes is 10 to 90% of the total area of the end surface , using either a metal mold, a laser beam, or a jet water stream. A method for producing a porous structure, wherein the through hole is formed. It is a manufacturing method of the porous structure of Claim 11 , Comprising: The pellet which has a core sheath structure whose core component consists of carbon fiber, and a sheath component consists of a 1st thermoplastic resin, and said 1st at predetermined temperature The composite material is manufactured by melting a second thermoplastic resin having a higher viscosity than that of the thermoplastic resin and kneading the melted pellets and the second thermoplastic resin at the predetermined temperature. further comprising the step, when the melting point of the second thermoplastic resin and T _2, porous wherein the pellets and the second thermoplastic resin is kneaded in a temperature range of T _{2 +} 10~T _{2 + 70} ℃ Manufacturing method of structure.

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