JP6207396B2 - 二次強化用適合性キャリヤー - Google Patents
二次強化用適合性キャリヤー Download PDFInfo
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- JP6207396B2 JP6207396B2 JP2013537728A JP2013537728A JP6207396B2 JP 6207396 B2 JP6207396 B2 JP 6207396B2 JP 2013537728 A JP2013537728 A JP 2013537728A JP 2013537728 A JP2013537728 A JP 2013537728A JP 6207396 B2 JP6207396 B2 JP 6207396B2
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Images
Classifications
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- D—TEXTILES; PAPER
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- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
- B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/246—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using polymer based synthetic fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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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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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/673—Including particulate material other than fiber
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Reinforced Plastic Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Other Resins Obtained By Reactions Not Involving Carbon-To-Carbon Unsaturated Bonds (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
Description
トランスファー モールディング(RTM)、シーマン コンポジット レジン インフュージョン プロセス(SCRIMP)、バキュム アシスト レジン インフュージョン(VARI)及びバキュム アシスト レジン トランスファー モールディング(VARTM)を含む。
(i)少なくとも一種の原樹脂、(ii)原樹脂の至る所に分配された第一の材料であって、該樹脂に少なくとも部分的に溶解する材料、及び(iii)原樹脂の至る所に分配された第二の材料であって、該樹脂に不溶性である材料を含み、
第一の材料と第二の材料が組み合わせ物とし原樹脂中に導入され、第一の材料と第二の材料が強化剤である、上記複合材料物品が本明細書に開示される。組み合わせ物は、熱可
塑性樹脂/ゴムの組み合わせ物、熱可塑性樹脂/熱可塑性樹脂の組み合わせ物、熱可塑性樹脂/クレーの組み合わせ物または熱可塑性樹脂/架橋ポリマーの組み合わせ物の一つであることができる。
らかにされた。これが、数ある利益の中でも、硬化材料の破壊抵抗性の向上に移行される。さらに、キャリヤー/剤の組み合わせ物から構成される繊維をベースとするシート材料を組み入れ、LRIプロセスにより製造された複合材料構造物は、数ある利益の中でも、衝撃強さ後に増大した圧縮力及び損傷面積/深さの低減を有することが実験的に明らかにされた。
Industries、Inc.より入手できる)、カーター(Carter)等の米国特許第7,192,634号明細書(その内容は、引用することにより本明細書に取り込まれる)に具体的に記載された材料のすべてを包含することができ、これらのすべてがエポキシ樹脂中で部分的に、実質的にまたは完全に溶解する。また別に、キャリヤーを含む材料は、限定されるものでないが、ポリ(メチルメタクリレート)(PMMA)、スチレン アセトニトリル(SAN)並びに、SAN/アクリレート ゴム(LURAN)及びPPE/St/Bu(LURANYL)のような市販のブレンドに加え、MMA/An/Bu/Stのコポリマーを包含することができ、これらのすべてがビニルエステル樹脂に部分的に、実質的にまたは完全に溶解する。
イバーまたは繊維網状構造、にかかわらず、剤の混入物は樹脂中(すなわち、硬化により)で一度は0.01ミクロン(μ)〜100ミクロン(μ)の直径を有する。
、その後、ベール上または内に分散することができる。次いで、組み合わせ物を積層して固定し、キャリヤー ベール繊維内に剤粒子をしっかりと閉じ込めることができる。
本発明の態様にしたがい、PMMA/コア−シェル粒子のキャリヤー/剤を用いてビニルエステル樹脂を強化した。PMMA及び強化粒子含有PMMAの両者を押出し、微細なフィラメントを作製した。硬化により、複合材を強化するために強化粒子含有PMMA中にコア−シェル粒子を残すようにPMMA繊維を溶解する.実験に基づく試験は以下の得られているデータをもたらした。
本発明の態様に従う、KM 180/ナイロン 粒子のキャリヤー/剤の組み合わせ物を用いてエポキシ樹脂を強化した。ナイロン4.6とKM 180(溶融290℃)を一緒に混合し、微細フィラメントを作製するまたの温度で押出した。この処理条件が、KM
180キャリヤー中に微細なナイロン粒子(剤)の埋め込まれた配合物をもたらした。実験に基づく試験は以下の得られているデータをもたらした。
本発明の態様に従う、KM 180/ナイロン フィブリルのキャリヤー/剤の組み合わせ物を用いてエポキシ樹脂を強化した。ナイロン6,6とKM 180を、10:90の比率で均質混合し、微細なフィラメントに押出した。この処理条件がKM 180キャリヤー中に埋め込まれたナイロン6,6フィブリル(剤)の網状構造物の形成をもたらした。実験に基づく試験は以下の得られているデータをもたらした。
溶解または凝集から剤の混在物を保護するように機能する。一般的に、二次的な強化剤を含有する可溶性キャリヤーは、それが特定の温度に達するとき未硬化熱硬化性樹脂中に溶解するように設計される。例えば、二次的な強化剤を有するPES/PEES可溶性繊維はエポキシ樹脂中に120℃(溶解温度)で溶解する。可溶性キャリヤーの溶解温度は、樹脂の硬化サイクル、すなわち、180℃より低い。この様式では、二次硬化剤は、早期というよりは、材料の硬化中にその場で放出される。
KM 180/ナイロン フィブリルのキャリヤー/剤の組み合わせ物を有するベールを組み入れる複合材料は、本発明の態様にしたがって製造した。ナイロン6,6のペレットとKM 180粉末を90:10(ナイロン:KM 180)の比率で一緒に配合した。得られたペレットを次に、溶融ブローして20gsmの溶融ブロー不織布ベールを形成した。実験に基づく試験は以下の得られているデータをもたらした。
図5は、生地プレフォームを備える代表的LRIアプローチ(例えば、柔軟な成形用具における樹脂インフュージョン(RIFT))を図解する。示されるように、この系は片面用具(すなわち、金型)504を含み、その上に置かれた繊維プレフォーム504を備える。剥離層506をプレフォーム504の表面に適用することができる。ガス抜き510をその中に有する真空バッグ508は、それの中にプレフォーム504を密閉し、プリフォームの存する「キャビティー」または領域を創製する。プレフォーム504が用具502上に置かれる前に、離型剤またはゲルコートを用具502の表面及び/または真空バッグ508の表面に適用することができる。一つの末端で、キャビティーを、樹脂移動ライン(示していない)を介して樹脂入口514に連結する。他端において、または同じ末端において、「キャビティー」真空排気ライン516を介して真空系(示していない)に結合する。プレフォーム504が用具502内に置かれると、真空が適用されると、液体樹脂518を周囲圧、予め決定した圧または勾配圧下で「キャビティー」内に注入することができる。液体樹脂518は周囲温度、予め決定した温度または温度勾配の元で注入することができる。いくつかの態様では、用具502及びプレフォーム504を、樹脂インジェクション前に、一般的には樹脂のインジェクション温度と同じ温度に加熱することができる。
複合材料部分の製造に使用することができる。靭性を高めるための熱可塑性樹脂の付加及び別のいくつかの配合物中に組み入れることのできない熱可塑性樹脂の付加は、熱硬化性樹脂系の粘度を損なうことなく上記のキャリヤー/剤の組み合わせ物により可能である。他の用途では、本発明に従うキャリヤー/剤の組み合わせ物は材料の粘度が再度等しく重要である塗料用途において有利に組込むことができる。他の用途では、前記態様に従うキャリヤー/剤の組み合わせ物は、安価な工具の作製(LCT)及びエンジンパーツの製造工程で使用することができる。
Claims (9)
- 複合材料品の製造方法において、
予め決定された温度範囲内で熱可塑性キャリヤー材料と強化材料を組み合わせ、押出して押出繊維を形成する工程、
押出繊維から少なくとも1つの不織ベールを形成する工程、
少なくとも1つの不織ベールと1以上の織物を組み合わせてマトリックス樹脂を含まないプレフォームを形成する工程、及び
液体熱硬化性樹脂をプレフォームに注入する工程であって、キャリヤー材料が該熱硬化性樹脂の少なくとも一部に溶解するが、強化材料は該熱硬化性樹脂に不溶のまま残存する、工程を含んでなり、かつ、
キャリヤー材料がポリエーテルスルホンとポリエーテルエーテルスルホンのコポリマーであり、強化材料がキャリヤー材料中に埋め込まれた粒子又はフィブリルの形状にあるポリアミドである、
ことを特徴とする方法。 - 樹脂注入後に樹脂の注入されたプレフォームを硬化する工程であって、硬化中に熱硬化性樹脂中に強化材料が不溶のまま残存している工程をさらに含む、請求項1に記載の方法。
- 強化材料がポリアミドフィブリルであり、該フィブリルがキャリヤー材料に溶解後多孔性フィブリル網状構造を形成する、請求項1または2に記載の方法。
- 請求項1に記載の方法において、プレフォームを金型内に置く工程、及び熱硬化性樹脂を注入する前に予め決定された温度に該金型を加熱する工程をさらに含む、方法。
- 請求項1に記載の方法において、熱硬化性樹脂がポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂、ビスマレイミド樹脂、ベンゾオキサジン樹脂、シアネートエステル樹脂、ビニルエステル樹脂、ポリイソシアヌレート樹脂、フェノール樹脂、及びそれらのいずれかの組み合わせ物の一つである、方法。
- 請求項1に記載の方法において、強化材料がキャリヤー材料の重量基準で0.001%〜50%である、方法。
- 樹脂注入を介して液体熱硬化性樹脂を受け取るためのものとして形成されたプレフォームであって、
マトリックス樹脂を含まない1層以上の織物、及び
予め決定された温度範囲内で熱可塑性キャリヤー材料と強化材料を組み合わせ、押出すことにより形成されている押出し繊維から構成された少なくとも1つの不織ベールを含んでなり、かつ、
キャリヤー材料がポリエーテルスルホンとポリエーテルエーテルスルホンのコポリマーであり、強化材料がキャリヤー材料中に埋め込まれた粒子又はフィブリルの形状にあるポリアミドであり、さらに
キャリヤー材料が予め決定された温度範囲内において該熱硬化性樹脂に少なくとも部分的に溶解性であり、強化材料が硬化サイクル中該熱硬化性樹脂に不溶性である、
ことを特徴とするプレフォーム。 - 強化材料がキャリヤー材料の重量基準で0.001%〜50%の範囲内にある、請求項7に記載のプレフォーム。
- 強化材料がポリアミドフィブリルである、請求項7に記載のプレフォーム。
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GB201322093D0 (en) * | 2013-12-13 | 2014-01-29 | Cytec Ind Inc | Compositive materials with electrically conductive and delamination resistant properties |
EP3086940A2 (en) * | 2013-12-23 | 2016-11-02 | Cytec Industries Inc. | Toughened composite materials and methods of manufacturing thereof |
EP3255083B1 (en) * | 2015-02-05 | 2021-09-15 | Toray Industries, Inc. | Preform, fiber-reinforced composite material, and method for manufacturing fiber-reinforced composite material |
BR112018009470B1 (pt) * | 2015-11-12 | 2022-04-12 | Cytec Industries Inc | Véu híbrido, laminado compósito, pré-forma fibrosa configurada para infusão de resina líquida, préimpregnado, fita fibrosa adequada para uso em um processo de assentamento de fita automatizada (atl) ou colocação de fibra automatizada (afp), tecido que pode ser infundido com uma resina líquida, tecido tecido que é permeável a líquido e gás |
JP6984414B2 (ja) * | 2016-02-23 | 2021-12-22 | 東レ株式会社 | 繊維強化複合材料の製造方法 |
CN109161161A (zh) * | 2018-08-10 | 2019-01-08 | 江苏恒神股份有限公司 | 一种高韧性非热压罐固化预浸料的生产工艺 |
CN109648890B (zh) * | 2018-12-25 | 2020-12-29 | 中国航空工业集团公司基础技术研究院 | 一种自支撑半浸渗自粘非屈曲预定型织物的制备方法 |
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CN111469446B (zh) * | 2020-04-17 | 2021-04-27 | 杭州卡涞复合材料科技有限公司 | 一种汽车复合材料防火电池箱的快速成型方法 |
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