JP6556286B2 - 複合材料を製造するための方法 - Google Patents
複合材料を製造するための方法 Download PDFInfo
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- JP6556286B2 JP6556286B2 JP2018077093A JP2018077093A JP6556286B2 JP 6556286 B2 JP6556286 B2 JP 6556286B2 JP 2018077093 A JP2018077093 A JP 2018077093A JP 2018077093 A JP2018077093 A JP 2018077093A JP 6556286 B2 JP6556286 B2 JP 6556286B2
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- Chemical Kinetics & Catalysis (AREA)
- Manufacturing & Machinery (AREA)
- General Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Reinforced Plastic Materials (AREA)
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Description
要約すれば、本発明の態様に係る方法は、
マトリクス物質と希釈剤を混合して、混合物を形成させる工程と、
混合物を強化繊維構造と接触させる工程と、
マトリクス物質の硬化の間にマトリクス物質から希釈剤を分離して、繊維強化複合材料を形成させる工程と、
を含む。
マトリクス物質の硬化をもたらすために、硬化剤が必要とされる場合、混合物が強化構造内にもたらされる前に、硬化剤は好ましくはマトリクス物質と混合されることが理解されるべきである。このための1つの理由は、マトリクス物質が強化繊維構造と接触する前に、マトリクス内に硬化剤を均一に分配し、混合しやすくするという事実に起因する。加えられる硬化剤の量は、マトリクス物質の製造業社により典型的に与えられる仕様により決定される。
希釈剤を選択する場合、マトリクス物質の混合物が、最初にマトリクス物質が有する粘度より低い粘度であるように、マトリクス物質より低い粘度を有するものを選択する。また、多くの場合、完全に硬化する前に、可能な限り多くの希釈剤がマトリクス物質から分離できるように、マトリクス物質と実質的に反応しない希釈剤を選択することが賢明である。しかしながら、比較的ゆっくり反応する限り、反応性希釈剤が使用されて、相当な量の希釈剤がマトリクス物質または任意の他の添加剤(例えば硬化剤、充填剤、染料、色素など)と反応する前に、マトリクス物質から分離されてもよいことが理解されるべきである。
混合物を強化繊維構造と接触させる多くの方法が存在し、それらのうちのいくつかは、例えば、強化構造内の混合物のより完全な分配を達成するために組み合わされてもよい。完全な分配とは、強化構造の実質的に全ての部分が混合物で湿潤し、また、繊維の間の到達しにくい小空間が混合物、それにより、マトリクス物質で満たされることを意味する(強化繊維構造内の混合物の分配の間、マトリクス物質が混合物内に均一に分配すると仮定する)。
繊維構造に完全に浸透させるために、十分な混合物が強化繊維構造に分配されると、希釈剤およびマトリクス物質の分離が、例えば、中間材料内部から希釈剤にエネルギーを付与することによってアクティブに促進され得る。
混合物は強化構造内を自由に移動できないので、圧力差が、混合物内、また、液体もしくはゲル化マトリクス物質内で生じ得る。例えば、混合物の過圧注入がモールド内の加圧と共に使用される場合、マトリクス物質の圧力は、モールド内の強化構造内にさらに移動している混合物内に存在するよりも、マトリクス物質の圧力はモールドの入口に非常に近接する。
エネルギーを付与するいくつかの方法が存在し、それらのうちの全てはそれら独自の利点をもたらし、それらの一部のものは一緒に使用するのに好適である。
強化繊維構造は、ウェブ、マット、バンドもしくは他の繊維構造、またはそのような構造の組み合わせであってもよい。強化繊維としての使用に好適な典型的な繊維は、炭素、ガラス、アラミドおよびケブラー(Kevlar)繊維であるが、強度、温度耐性、伝導性などのそれらの物理特性に依存して、他の繊維が好適であってもよい。
上述のように、硬化剤が使用される場合、マトリクス物質の硬化は、好ましくは、マトリクス物質が強化繊維構造と接触する前に開始される。そのような場合、硬化プロセスは、エポキシなどのマトリクス物質と、硬化剤との間の化学プロセスである。そのような硬化プロセスは、時々、適度な量の加熱によりわずかに加速され得る。また、硬化プロセスは典型的に発熱反応であり、熱は硬化プロセス自体の化学反応により生成され、可能な場合には、均一で急速な硬化プロセスを導き、温度が非常に高い場合、材料損傷の危険性があることが言及されるべきである。
希釈剤の選択は、ほとんどはマトリクス物質の選択に依存し、次にマトリクス物質の所望の特性(例えば高強度、低価格、強化繊維材料に対する十分な接着、十分な耐食性、低い毒性など)に依存する。
モールドは、製造される複合材料の形状を規定し、および/または混合物を強化繊維構造と接触させるプロセスを行うために使用され得る。ここで、複合材料の形状を規定する目的のために例えモールドが使用されなくても、中間材料を形成するために混合物を強化繊維構造と接触させるプロセスを行う閉じることができる容量としてモールドが使用されてもよく、中間材料がモールドから除去され得た後、次いでさらに処理および/または硬化されることは理解されるべきである。したがって、モールドは、製造される複合材料の形状を規定するためにのみ使用されてもよく、その場合、中間材料はモールドの外側で製造され、次いでモールドに入れられてもよい。
ここで、本発明の一実施形態に係る方法を実施するためのシステムSを図1を参照して記載する。システムSは3つの流体コンテナを備える。第1の流体コンテナ1はマトリクス物質Aを保存するように構成され、第2の流体コンテナ2は希釈剤Bを保存するように構成され、第3の流体コンテナ3は硬化剤Cを保存するように構成される。
最初に、3つのコンテナ1、2、3をエポキシ基剤A、エタノールBおよびエポキシ硬化剤Cでそれぞれ満たす。次いで、モールドを開口し、複数の層または炭素繊維ウェブを含む強化繊維構造Fを安定なサイズに切断し、コアD周囲のモールドキャビティに配置し、その後、モールド8を閉じ、油圧プレス11により圧力下に置く。真空システム15および混合メーター7をモールドに接続し、真空システム15をアクティブにして、モールドキャビティおよび全ての穴ならびにモールドキャビティと流体連絡する他の空間の内側に真空様雰囲気を与える。一旦、真空様雰囲気を達成すると、ポンプ4、5、6および混合メーター7をアクティブにして、高圧下でモールドキャビティ内に混合物を供給し、それにより、強化繊維構造Fは、中間材料を形成するために混合物により完全に浸透される。一旦、モールドキャビティが混合物で満たされると、エネルギー供給装置16をアクティブにして、強化繊維構造F内の電気接続した炭素繊維を抵抗加熱し、それにより、エタノールBを、中間材料内の混合したエポキシA+Cから分離する。蒸発したエタノールBは、真空システム15を使用してモールド8の出口10を介してモールドキャビティから出ていく。一旦、実質的に全てのエタノールBが混合したエポキシA+Cから分離し、排出されると、過熱せずに混合したエポキシA+Cの迅速な硬化を促進するために抵抗加熱が適切なレベルで適用される。
Claims (9)
- エポキシマトリクス物質を強化繊維構造と接触させて、中間材料を形成させる工程であって、該中間材料の形成を実施している少なくとも一部の間、前記強化繊維構造はモールドに配置され、前記中間材料内部から、前記エポキシマトリクス物質の部分を、前記中間材料中の混合物中の希釈剤の沸点以下に加熱するエネルギーが付与される工程[a]と、
前記中間材料の前記エポキシマトリクス物質を硬化させて、複合材料を形成させる工程[b]と、
工程[a]の前に前記エポキシマトリクス物質と希釈剤を混合して、混合物を形成させる工程[c]と、
工程[b]の間に、前記中間材料内部から希釈剤にエネルギーを付与することによって前記エポキシマトリクス物質から希釈剤を分離する工程[d]と、
を含み、
前記強化繊維構造は複数の強化繊維を含み、前記エポキシマトリクス物質は、前記強化繊維構造の繊維の間の結合剤として作用するように前記強化繊維構造内に分配され、前記複合材料は、65%より多い繊維体積分率(FVF)を有し、
工程[d]は、前記強化繊維構造が導電性繊維を含んで、少なくとも部分的に、前記強化繊維構造の部分の局所的加熱が、強化繊維との直接的な電気接触を必要とせずに実施されることによって前記導電性繊維を介して電流を伝導するステップによって実施されるか、または、工程[d]は、前記強化繊維構造が導電性繊維を含まずに、少なくとも部分的に、前記エポキシマトリクス物質から前記希釈剤を分離させるために前記中間材料にマイクロ波を与えるステップによって実施される、
繊維強化プラスチック複合材料を製造する方法。 - 前記中間材料が、工程[d]を実施するためにモールドに配置される前に製造される、請求項1に記載の方法。
- 少なくとも工程[a]を実施する間、前記モールドに圧力がかけられるステップ、
少なくとも工程[a]を実施する間、真空様雰囲気が、前記モールドに提供されるステップ、および
前記強化繊維構造内への前記エポキシマトリクス物質の過圧注入ステップ、
のうち少なくともいずれか一つを含んで工程[a]が実施される請求項1に記載の方法。 - 工程[d]を実施する間、前記モールドに圧力がかけられる、請求項2に記載の方法。
- 1つ以上のモールドキャビティ表面が断熱されるか、電気絶縁されるか、断熱かつ電気絶縁される請求項2、3または4に記載の方法。
- 前記モールドが、プラスチックから作製され、該プラスチックが、ポリオキシメチレン、ポリテトラフルオロエチレンおよびポリエチレンテレフタレートからなる群より選択される、請求項2〜5のいずれか一項に記載の方法。
- 前記希釈剤が、前記エポキシマトリクス物質に対して反応しない希釈剤であり、該希釈剤が、メタノール、エタノール、プロパノール、ブタノール、ペンタノール、ヘキサノール、およびヘプタノールからなる群より選択されるアルコールである、請求項1〜6のいずれか一項に記載の方法。
- 前記混合物が、体積で1〜70%の希釈剤を含む、請求項1〜7のいずれか一項に記載の方法。
- 前記強化繊維構造が、導電性繊維を含む場合、前記強化繊維構造の少なくとも30重量%の炭素繊維含有量を有する、請求項1〜8のいずれか一項に記載の方法。
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CA2778505A1 (en) | 2011-04-28 |
JP2018138385A (ja) | 2018-09-06 |
MX2012004752A (es) | 2012-07-30 |
WO2011048216A1 (en) | 2011-04-28 |
AU2010309771A1 (en) | 2012-06-14 |
BR112012009390A2 (pt) | 2018-12-26 |
CN102695598A (zh) | 2012-09-26 |
JP2016005912A (ja) | 2016-01-14 |
ES2632927T3 (es) | 2017-09-18 |
RU2587171C2 (ru) | 2016-06-20 |
EP2490883A1 (en) | 2012-08-29 |
RU2587171C9 (ru) | 2016-09-27 |
RU2012118071A (ru) | 2013-11-27 |
EP2490883B1 (en) | 2017-04-12 |
CN102695598B (zh) | 2015-08-12 |
PT2490883T (pt) | 2017-07-17 |
SE534361C2 (sv) | 2011-07-26 |
CA2778505C (en) | 2018-05-01 |
KR101849707B1 (ko) | 2018-04-17 |
US20130130583A1 (en) | 2013-05-23 |
JP2013508191A (ja) | 2013-03-07 |
KR20120099692A (ko) | 2012-09-11 |
SE0950790A1 (sv) | 2011-04-24 |
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