JP6789415B2 - コンポジット成形材料 - Google Patents
コンポジット成形材料 Download PDFInfo
- Publication number
- JP6789415B2 JP6789415B2 JP2019562416A JP2019562416A JP6789415B2 JP 6789415 B2 JP6789415 B2 JP 6789415B2 JP 2019562416 A JP2019562416 A JP 2019562416A JP 2019562416 A JP2019562416 A JP 2019562416A JP 6789415 B2 JP6789415 B2 JP 6789415B2
- Authority
- JP
- Japan
- Prior art keywords
- graphene
- graphite
- resin
- molding material
- composite molding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000002131 composite material Substances 0.000 title claims description 109
- 239000012778 molding material Substances 0.000 title claims description 79
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 300
- 229910021389 graphene Inorganic materials 0.000 claims description 227
- 239000000835 fiber Substances 0.000 claims description 111
- 239000000463 material Substances 0.000 claims description 103
- 229910002804 graphite Inorganic materials 0.000 claims description 67
- 239000010439 graphite Substances 0.000 claims description 67
- 239000006185 dispersion Substances 0.000 claims description 66
- 229920005989 resin Polymers 0.000 claims description 60
- 239000011347 resin Substances 0.000 claims description 60
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- 238000010438 heat treatment Methods 0.000 claims description 14
- 230000001788 irregular Effects 0.000 claims description 13
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 claims description 12
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 12
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 11
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- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 claims description 9
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 9
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 claims description 9
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 claims description 9
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 claims description 9
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 9
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 claims description 9
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- FFWSICBKRCICMR-UHFFFAOYSA-N 5-methyl-2-hexanone Chemical compound CC(C)CCC(C)=O FFWSICBKRCICMR-UHFFFAOYSA-N 0.000 claims description 6
- IAZDPXIOMUYVGZ-UHFFFAOYSA-N Dimethylsulphoxide Chemical compound CS(C)=O IAZDPXIOMUYVGZ-UHFFFAOYSA-N 0.000 claims description 6
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- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 claims description 6
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- XNLICIUVMPYHGG-UHFFFAOYSA-N pentan-2-one Chemical compound CCCC(C)=O XNLICIUVMPYHGG-UHFFFAOYSA-N 0.000 claims description 6
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- PAPBSGBWRJIAAV-UHFFFAOYSA-N ε-Caprolactone Chemical compound O=C1CCCCCO1 PAPBSGBWRJIAAV-UHFFFAOYSA-N 0.000 claims description 5
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 claims description 4
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
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- NTIZESTWPVYFNL-UHFFFAOYSA-N Methyl isobutyl ketone Chemical compound CC(C)CC(C)=O NTIZESTWPVYFNL-UHFFFAOYSA-N 0.000 claims description 3
- UIHCLUNTQKBZGK-UHFFFAOYSA-N Methyl isobutyl ketone Natural products CCC(C)C(C)=O UIHCLUNTQKBZGK-UHFFFAOYSA-N 0.000 claims description 3
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- WMOVHXAZOJBABW-UHFFFAOYSA-N tert-butyl acetate Chemical compound CC(=O)OC(C)(C)C WMOVHXAZOJBABW-UHFFFAOYSA-N 0.000 claims description 2
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Images
Classifications
-
- 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
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/10—Reinforcing macromolecular compounds with loose or coherent fibrous material characterised by the additives used in the polymer mixture
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
-
- 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
- B29C70/02—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
- B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
- B29C70/025—Combinations of fibrous reinforcement and non-fibrous material with particular filler
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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
- B29C70/02—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
- B29C70/028—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 and with one or more layers of non-plastics material or non-specified material, e.g. supports
-
- 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
- B29C70/06—Fibrous reinforcements only
-
- 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
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Description
本発明は、コンポジット成形材料、及び特にグラフェン及び/又はグラファイトを含む繊維強化コンポジット成形材料の製造に関する。
繊維強化コンポジット(FRC)は、それらが比較的軽量であり、面内固有の強度と剛性が高いため、多くの製造分野、特に高強度/軽量構造の製造で広く使用されている。
本発明の一態様によれば、繊維層と、前記繊維層の表面上の1つ以上の局所領域で前記繊維層に塗布されたグラフェン/グラファイト状材料と、を含むコンポジット成形材料の製造方法であって、
前記グラフェン/グラファイト状材料が、グラフェンナノプレート、グラフェンオキシドナノプレート、還元型グラフェンオキシドナノプレート、二層グラフェンナノプレート、二層グラフェンオキシドナノプレート、二層還元型グラフェンオキシドナノプレート、少数層グラフェンナノプレート、少数層グラフェンオキシドナノプレート、少数層還元型グラフェンオキシドナノプレート、炭素原子6〜14層のグラフェン/グラファイトナノプレート、ナノスケール寸法と炭素原子40層以下とを有するグラファイトフレーク、ナノスケール寸法と炭素原子25〜30層とを有するグラファイトフレーク、ナノスケール寸法と炭素原子25〜35層とを有するグラファイトフレーク、ナノスケール寸法と炭素原子20〜35層とを有するグラファイトフレーク、又はナノスケール寸法と炭素原子20〜40層とを有するグラファイトフレークから構成され、且つ前記分散液は、少なくとも1つのバルブジェットプリントヘッドを使用して前記繊維層に塗布される、コンポジット成形材料の製造方法が提供される。
本発明の好ましい実施形態を、添付の図面を参照して、ほんの一例として以下に説明する。
本発明は、繊維層と、前記繊維層の表面上の1つ以上の局所領域で前記繊維層に塗布されたグラフェン/グラファイト状分散液とを含むコンポジット成形材料の製造方法を提供する。ここで、前記分散液は2つ以上のバルブジェットプリントヘッドを使用して塗布される。
還元グラフェン酸化物のうちの1つ又は複数を含んでもよい。
複数の繊維層と、前記繊維層を強化する硬化性マトリックス樹脂とを提供すること、
前記繊維層のうち少なくとも1つの表面上の1つ以上の局所領域にグラフェン/グラファイト状分散液を塗布すること、
前記分散液から生じる前記グラフェン/グラファイト状材料が2つの隣接する繊維層の間に位置するように前記繊維層を位置決めすること、及び
前記繊維材料の周りの前記マトリックス樹脂を硬化させる条件に前記コンポーネントを曝露すること、を含む。
Claims (19)
- 繊維層と、前記繊維層の表面上の1つ以上の局所領域で前記繊維層に塗布されたグラフェン/グラファイト状分散液と、を含むコンポジット成形材料の製造方法であって、
前記グラフェン/グラファイト状分散液が、グラフェンナノプレート、グラフェンオキシドナノプレート、還元型グラフェンオキシドナノプレート、二層グラフェンナノプレート、二層グラフェンオキシドナノプレート、二層還元型グラフェンオキシドナノプレート、多層グラフェンナノプレート、多層グラフェンオキシドナノプレート、多層還元型グラフェンオキシドナノプレート、炭素原子6〜14層のグラフェン/グラファイトナノプレート、炭素原子40層以下を有するグラファイトフレーク、炭素原子25〜30層を有するグラファイトフレーク、炭素原子25〜35層を有するグラファイトフレーク、炭素原子20〜35層を有するグラファイトフレーク、又は炭素原子20〜40層を有するグラファイトフレークから構成され、ここで、前記分散液は、少なくとも1つのバルブジェットプリントヘッドを使用して前記繊維層に塗布される、コンポジット成形材料の製造方法。 - 1つ以上のバルブジェットプリントヘッドは、50μm〜600μmの間、50μm、100μm、150μm、200μm、300μm、400μm又は600μmのノズル直径を有する、請求項1に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト分散液が、前記又は各バルブジェットプリントヘッドを介して塗布する前に、最大689.5kPa、最大2757.9kPa、又は最大4826.3kPaの圧力に加圧されるか、又は圧力で貯蔵される、請求項2に記載のコンポジット成形材料の製造方法。
- 1つ以上のバルブジェットプリントヘッドが加熱手段を有する、請求項1〜3のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト分散液が塗布前にリザーバに貯蔵され、且つ前記リザーバに加熱手段が設けられている、請求項1〜4のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状分散液を前記1つ以上の局所領域に塗布するため、前記又は各バルブジェットプリントヘッドが前記繊維層に対して移動するか、又は前記グラフェン/グラファイト状分散液を前記1つ以上の局所領域に塗布するため、前記繊維層が、前記又は各バルブジェットプリントヘッドに対して移動する、請求項1〜5のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状分散液を前記1つ以上の局所領域に塗布するため、前記又は各バルブジェットプリントヘッド及び前記繊維層の両方が互いに対して移動してよい、請求項1〜5のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記又は各バルブジェットプリントヘッド及び前記繊維層の移動の方向が互いに90°である、請求項7に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状材料が、前記繊維層の表面上の少なくとも1つの所定の領域に選択的に配置され得る、請求項1〜8のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記領域が互いに間隔を置いて不連続である、請求項1〜9のいずれか一項に記載のコンポジット成形材料の製造方法。
- 請求項1〜10のいずれか一項に記載のコンポジット成形材料の製造方法であって、少なくとも1つの領域が、0.01mm2〜1.5mm2、0.01mm2〜1.0mm2、0.5mm2〜1.5mm2、0.5mm2より大きい、又は1mm2より大きい、前記繊維層上の表面積をカバーしている、コンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状材料が、前記繊維層の表面上の領域のアレイ又はパターンにおいて、又はその中に配置され得る、請求項1〜11のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記アレイ又はパターンが、規則的なアレイ、不規則なアレイ、又は部分的に規則的であり、且つ他の部分は不規則であるアレイである、請求項12に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状材料が、グラフェン/グラファイトの複数の層を含むプレートレットを含み、且つ0.8から12ナノメートル、1.3から9.4ナノメートル、又は2.5から6ナノメートルの平均厚さを有する、請求項1〜13のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記グラフェン/グラファイト状材料が、最大25層のグラフェン、最大35層のグラフェン、5〜25層のグラフェン、5〜35層のグラフェン、5〜15層のグラフェン、又は25〜35層のグラフェンのプレートレットを含む、請求項1〜14のいずれか一項に記載のコンポジット成形材料の製造方法。
- 請求項1〜15のいずれか一項に記載のコンポジット成形材料の製造方法であって、
前記グラフェン/グラファイト状材料がキャリア媒体を含み、
前記キャリア媒体が、樹脂、熱硬化性樹脂、エポキシ樹脂、ポリエステル(不飽和)樹脂、フェノール樹脂、ビニルエステル樹脂、ポリウレタン樹脂、シリコーン樹脂、ポリアミド樹脂、ポリアミドイミド樹脂、ビスマレイミド樹脂、シアネートエステル樹脂、ベンゾオキサジン樹脂、熱可塑性樹脂、ポリエチレン(PE)樹脂、ポリエチレンテレフタレート(PET)樹脂、ポリブチレンテレフタレート(PBT)樹脂、ポリカーボネート(PC)樹脂、アクリロニトリルブタジエンスチレン(ABS)樹脂、ポリアミド(PA又はナイロン)樹脂、ポリプロピレン(PP)樹脂、高性能熱可塑性樹脂、ポリエーテルエーテルケトン(PEEK)樹脂、ポリエーテルケトン(PEK)樹脂、ポリアミドイミド(PAI)樹脂、ポリアリールスルホン(PAS)樹脂、ポリエーテルイミド(PEI)樹脂、ポリエーテルスルホン(PES)樹脂、ポリフェニレンスルフィド(PPS)樹脂、バイオベースの樹脂、デンプンからなるバイオベースの樹脂、デンプンカプロラクトンブレンドからなるバイオベースの樹脂、ポリエステルからなるバイオベースの樹脂、ポリコハク酸アルキレンからなるバイオベースの樹脂、ポリエステルアミドからなるバイオベースの樹脂、ポリヒドロキシアルカノエートからなるバイオベースの樹脂、ポリビニルブチラールからなるバイオベースの樹脂、ポリビニルバレエートからなるバイオベースの樹脂、ポリヒドロキシ酸からなるバイオベースの樹脂、ポリ乳酸からなるバイオベースの樹脂、ポリグリコール酸からなるバイオベースの樹脂、セルロースアセテートからなるバイオベースの樹脂、フルフラールアルコールからなるバイオベースの樹脂、フラン樹脂からなるバイオベースの樹脂、油変性ポリエステルからなるバイオベースの樹脂、植物油変性からなるバイオベースの樹脂、カシューナッツ油の変性からなるバイオベースの樹脂、脱イオン水、溶媒、ヘキサン、ベンゼン、トルエン、キシレン、ジエチルエーテル、1,4−ジオキサン、酢酸エチル、n−ブチルアセテート、t−ブチルアセテート、エチルエトキシプロピオネート、プロピレングリコールモノメチルエーテルアセテート、酢酸メチル、ジメチルカーボネート、テトラヒドロフラン、ジクロロメタン、アセトン、メチルエチルケトン、メチルイソブチルケトン、メチルプロピルケトン、メチルイソアミルケトン、アセトニトリル、ジメチルホルムアミド、ジメチルスルホキシド、n−ブタノール、メタノール、エタノール、n−プロパノール、イソプロパノール、ブタノール、グリコール−エチレングリコール、プロピレングリコール、パラクロロベンゾトリフルオライド、結晶性材料もしくは半結晶性材料、熱可塑性高分子量線状飽和コポリエステル、のうちの1つ、又は上記のうちの2つ以上の混合物もしくは組み合わせ、を含んでもよい、コンポジット成形材料の製造方法。 - 前記グラフェン/グラファイト状分散液が、0.001重量%から10重量%、0.001重量%から1重量%、0.01重量%から0.5重量%、又は0.01重量%から5重量%の範囲のグラフェン/グラファイト含有量を有する、請求項1〜16のいずれか一項に記載のコンポジット成形材料の製造方法。
- 前記繊維層に塗布されたグラフェン/グラファイト状分散液は、1mg/m2から35000mg/m2、1mg/m2から2000mg/m2、10mg/m2から100mg/m2、1000mg/m2から20000mg/m2、1000mg/m2から10000mg/m2、又は10mg/m2から20mg/m2の範囲の面積密度を有する、請求項1〜17のいずれか一項に記載のコンポジット成形材料の製造方法。
- 請求項1〜18のいずれかに記載のコンポジット成形材料の製造方法であって、前記グラフェン/グラファイト状分散液が、10 Υ.(s−1)@ 23℃において測定された、1〜75センチポアズ、1〜10000センチポアズ、1〜7500センチポアズ、10〜50センチポアズ、80〜10000センチポアズ、80〜7500センチポアズ、350〜10000センチポアズ、350〜7500センチポアズ、20センチポアズ、又は300センチポアズの粘度を有する、コンポジット成形材料の製造方法。
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GB2572270A (en) | 2019-09-25 |
WO2018206938A1 (en) | 2018-11-15 |
EP3609950B1 (en) | 2024-03-27 |
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US20200123331A1 (en) | 2020-04-23 |
SG10202112162SA (en) | 2021-12-30 |
US20200269522A1 (en) | 2020-08-27 |
KR102535369B1 (ko) | 2023-05-22 |
KR20200005612A (ko) | 2020-01-15 |
GB2564525A (en) | 2019-01-16 |
GB2564525B (en) | 2020-03-25 |
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WO2018206938A9 (en) | 2019-11-28 |
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