JP6479340B2 - 炭素繊維複合材 - Google Patents
炭素繊維複合材 Download PDFInfo
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims description 175
- 229920000049 Carbon (fiber) Polymers 0.000 title claims description 172
- 239000004917 carbon fiber Substances 0.000 title claims description 172
- 239000002131 composite material Substances 0.000 title claims description 79
- 229920005989 resin Polymers 0.000 claims description 32
- 239000011347 resin Substances 0.000 claims description 32
- 229920001187 thermosetting polymer Polymers 0.000 claims description 27
- 239000006260 foam Substances 0.000 claims description 26
- 238000007906 compression Methods 0.000 claims description 15
- 230000006835 compression Effects 0.000 claims description 15
- 239000011148 porous material Substances 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 11
- 239000000835 fiber Substances 0.000 claims description 9
- 239000004640 Melamine resin Substances 0.000 claims description 6
- 229920000877 Melamine resin Polymers 0.000 claims description 6
- 239000002759 woven fabric Substances 0.000 claims description 6
- 229920006122 polyamide resin Polymers 0.000 claims description 3
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 description 9
- 239000004744 fabric Substances 0.000 description 7
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 6
- 238000003825 pressing Methods 0.000 description 6
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- 238000000465 moulding Methods 0.000 description 4
- 229920001568 phenolic resin Polymers 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 239000003063 flame retardant Substances 0.000 description 3
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- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000005007 epoxy-phenolic resin Substances 0.000 description 2
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 2
- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
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- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
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- 238000004040 coloring Methods 0.000 description 1
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- 238000005034 decoration Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 235000010299 hexamethylene tetramine Nutrition 0.000 description 1
- 239000004312 hexamethylene tetramine Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
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Description
請求項1の発明によれば、複数の炭素繊維プリプレグと多孔質プリプレグは平面視同一形状からなるため、凹部及び凸部を賦形するために形状の異なる多種類の炭素繊維プリプレグや多孔質プリプレグを積層する必要がなくなり、凹凸の賦形が容易になると共に、製品内の寸法ばらつきを抑えることができ、量産性が高まるとともに、作業工数の削減につながる。
前記炭素繊維プリプレグ11、13は、炭素繊維織物に熱硬化性樹脂が含浸したものからなる。前記炭素繊維織物は、軽量及び高剛性に優れるものであり、特に、繊維が一方向のみではない織り方のものが好ましく、例えば、縦糸と横糸で構成される平織、綾織、朱子織及び3方向の糸で構成される三軸織などが好適である。また、前記炭素繊維織物は、熱硬化性樹脂の含浸及び剛性の点から、繊維重さが50〜600g/m2のものが好ましい。
多孔質材としては、発泡体を挙げることができる。発泡体としては連続気泡構造からなる発泡体が適し、例えば、ウレタン樹脂発泡体、メラミン樹脂発泡体、ポリオレフィン(ポリアミド)発泡体等から選択することができる。発泡体は連続気泡であることで、熱硬化性樹脂が含浸できるだけでなく、高い圧縮率で成形が可能となる。上記素材を多孔質材として選ぶことにより炭素繊維織物を積層した厚みにまで圧縮成形が可能である。特に、前記多孔質材として、メラミン樹脂発泡体もしくはポリアミド樹脂発泡体が好ましい。また、前記炭素繊維複合材10に難燃性が求められる場合には、前記多孔質材としては難燃性のものが好ましく、メラミン樹脂発泡体は良好な難燃性を有するため、前記多孔質材として好適なものである。前記多孔質材の圧縮前の元厚みは適宜設定され、例えば1〜25mmを挙げる。また、前記多孔質材が発泡体からなる場合、発泡体は圧縮容易性、含浸性、軽量性、剛性の点から、圧縮前の密度が5〜80kg/m3のものが好ましい。
図1の炭素繊維複合材10を成形する例を示す。熱硬化性樹脂としてフェノール樹脂(旭有機材料株式会社製、品名;PAPS−4と旭有機材料株式会社製、品名;ヘキサメチレンテトラミンを100:12で混合したもの)をメタノールに30wt%の濃度となるように溶解した。このフェノール樹脂溶液中に平織の炭素繊維織物(東邦テックス株式会社製、品名;W−3101、繊維重さ200g/m2)を漬け、取り出した後に25℃の室温にて2時間自然乾燥し、更に60℃の雰囲気下にて1時間乾燥させて炭素繊維プリプレグを2枚形成した。炭素繊維織物は、200×300mmの平面サイズに裁断したもの(重量12g/枚)を使用した。
図5の炭素繊維複合材50を成形する例を示す。実施例1と同様にして炭素繊維プリプレグを8枚形成し、また多孔質プリプレグを2枚形成した。
次に、予め離型剤を表面に塗布したSUS製の下側金型上に、図8に示した積層順序で、炭素繊維プリプレグと多孔質プリプレグを順に積層して配置し、下側金型上の積層体を、型面に凹部形成用の突起と凸部形成用の窪みが形成された上側金型により、180℃で3分間、5MPaの面圧をかけて押圧し、圧縮及び加熱を行ない、前記圧縮状態でフェノール樹脂を反応硬化させた。その際の加熱は、上下金型に取り付けられた鋳込みヒーターにより行なった。圧縮後の厚みは、製品形状に応じて平板を形成する一般部に応じてキャビティを設計した。その後、上下金型を室温で冷却させた後に開き、前記炭素繊維プリプレグと多孔質プリプレグが積層一体化した炭素繊維複合材を得た。その後、炭素繊維複合材の周囲の余剰部分をカットするトリミングを行い、図5の炭素繊維複合材50を得た。
前記複数の炭素繊維プリプレグと前記多孔質プリプレグは、平面視形状が同一である場合に限られず、成形する製品の形状に応じて、積層位置に応じて、上記2種類のプリプレグの平面形状を、裁断、設計することができる。特に多孔質プリプレグの平面視形状を、その積層位置に応じて、裁断、設計することができる。
11、13、51〜58、82A〜82D、83A〜83D 炭素繊維プリプレグ
21、61、62、81A、81B 多孔質プリプレグ
101、103、501、503 凹部
502、504、506、85、87 凸部
111、511、811 一般部
Claims (6)
- 繊維が一方向のみではない縦糸と横糸で構成される織り方からなる炭素繊維織物に熱硬化性樹脂が含浸した炭素繊維プリプレグの複数枚と、連続気泡構造の発泡体からなる多孔質材に前記熱硬化性樹脂と同じ熱硬化性樹脂が含浸した多孔質プリプレグの少なくとも1枚が積層されて加熱、加圧により全面圧縮されて、前記炭素繊維プリプレグと多孔質プリプレグに含浸している熱硬化性樹脂が硬化して前記炭素繊維プリプレグと前記多孔質プリプレグが一体化されて形状が固定された炭素繊維複合材であって、
前記多孔質材の圧縮前の元厚みは1〜25mmであり、
前記連続気泡構造の発泡体は、メラミン樹脂発泡体、ポリアミド樹脂発泡体、又はウレタン樹脂発泡体の何れかであり、
前記複数の炭素繊維プリプレグと前記多孔質プリプレグは平面視同一形状からなり、
前記多孔質プリプレグが前記炭素繊維プリプレグ間に配置されて前記炭素繊維複合材の表面が前記炭素繊維プリプレグで構成され、
前記炭素繊維製品複合材の最終形状に応じて平板となる一般部が賦形され、前記炭素繊維複合材の少なくとも一側の表面には凹部と凸部の何れか一方又は両方が賦形され、
前記凹部のみが賦形された場合、前記凹部の無い一般部と比べて前記凹部では前記多孔質プリプレグの厚みが減少し、
前記凸部のみが賦形された場合、前記凸部の無い一般部と比べて前記凸部では前記多孔質プリプレグの厚みが増大し、
前記凹部と凸部の両方が賦形された場合、前記凹部及び凸部の無い一般部と比べて前記凹部では前記多孔質プリプレグの厚みが減少し、前記凸部では前記多孔質プリプレグの厚みが増大していることを特徴とする炭素繊維複合材。 - 前記連続気泡構造の発泡体の圧縮前の密度は、5〜80kg/m 3 であり、
前記凹部のみが賦形された場合、前記凹部の無い一般部と比べて前記凹部では前記炭素繊維複合材の厚みが減少し、
前記凸部のみが賦形された場合、前記凸部の無い一般部と比べて前記凸部では前記炭素繊維複合材の厚みが増大し、
前記凹部と凸部の両方が賦形された場合、前記凹部及び凸部の無い一般部と比べて前記凹部では前記炭素繊維複合材の厚みが減少し、前記凸部では前記炭素繊維複合材の厚みが増大していることを特徴とする請求項1に記載の炭素繊維複合材。 - 前記凹部及び凸部の反対側の表面は凹凸の無い平面からなることを特徴とする請求項1又は2に記載の炭素繊維複合材。
- 前記多孔質プリプレグは、複数枚重なって前記炭素繊維プリプレグ間に配置されていることを特徴とする請求項1から3の何れか一項に記載の炭素繊維複合材。
- 前記炭素繊維複合材の一側の表面と該表面に最も近い前記多孔質プリプレグまでの間に存在する前記炭素繊維プリプレグの枚数と、他側の表面と該表面に最も近い前記多孔質プリプレグまでの間に存在する前記炭素繊維プリプレグの枚数が等しいことを特徴とする請求項1から4の何れか一項に記載の炭素繊維複合材。
- 前記炭素繊維複合材の一側の表面と該表面に最も近い前記多孔質プリプレグまでの間に存在する前記炭素繊維プリプレグの枚数と、他側の表面と該表面に最も近い前記多孔質プリプレグまでの間に存在する前記炭素繊維プリプレグの枚数が異なることを特徴とする請求項1から4の何れか一項に記載の炭素繊維複合材。
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