JP6847510B2 - Carbon fiber composite veneer - Google Patents

Carbon fiber composite veneer Download PDF

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JP6847510B2
JP6847510B2 JP2016223909A JP2016223909A JP6847510B2 JP 6847510 B2 JP6847510 B2 JP 6847510B2 JP 2016223909 A JP2016223909 A JP 2016223909A JP 2016223909 A JP2016223909 A JP 2016223909A JP 6847510 B2 JP6847510 B2 JP 6847510B2
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carbon fiber
fiber composite
phenol resin
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woven fabric
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JP2018079630A (en
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中村　優
優 中村
尚幸 田辺
尚幸 田辺
杉浦　好典
好典 杉浦
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Inoac Corp
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本発明は、三次元的な曲げ形状の賦形が良好な炭素繊維複合化粧板に関する。 The present invention relates to a carbon fiber composite decorative board having a good three-dimensional bending shape.

従来、鉄道車両などの車両用部材には、軽量化の要求から、内装材などにはガラス繊維や炭素繊維などを用いた繊維強化複合材料（ＦＲＰ）の成形体が部分的に採用されている。さらに、車両用部材は、使用部位によっては三次元的な曲げ形状に賦形されたものが必要な場合があり、その場合には三次元的な曲げ形状部の表面に美観低下を生じないものが求められる。また、車両用部材には、不燃性及び軽量性も求められる。 Conventionally, fiber reinforced plastic (FRP) molded bodies using glass fiber, carbon fiber, etc. have been partially adopted for interior materials, etc., due to the demand for weight reduction in rolling stock members such as railroad vehicles. .. Further, the vehicle member may need to be shaped into a three-dimensional bent shape depending on the part to be used, and in that case, the surface of the three-dimensional bent shape portion does not deteriorate in appearance. Is required. In addition, vehicle members are also required to be nonflammable and lightweight.

特許文献１には、表面化粧層及び芯材層を有するメラミン樹脂層と、接着剤層と、金属層がこの順に積層されたメラミン樹脂金属化粧板について、ＪＩＳ Ｋ ６９０２の曲げ成形性試験（Ａ法）を行った実施例が記載されている。 Patent Document 1 describes a bend moldability test (A) of JIS K 6902 for a melamine resin metal decorative plate in which a melamine resin layer having a surface decorative layer and a core material layer, an adhesive layer, and a metal layer are laminated in this order. Examples of performing the method) are described.

特許文献２には、金属板の両表面に熱硬化性樹脂を含浸した繊維基材を重ね、更にそれぞれの表面にメラミン樹脂を含浸した繊維基材を重ね、加熱加圧成形した金属コア両面化粧板において、両表面のメラミン樹脂含浸繊維基材の一方又は両方に、ポリエステル繊維等の有機又は無機繊維不織布を使用したものについて、ＪＩＳ Ｋ ６９０２による耐屈曲性を測定した実施例が記載されている。 In Patent Document 2, a fiber base material impregnated with a thermosetting resin is superposed on both surfaces of a metal plate, and a fiber base material impregnated with a melamine resin is further superposed on each surface, and a metal core double-sided cosmetic molded by heating and pressurizing. An example is described in which the bending resistance of a board using an organic or inorganic fiber non-woven fabric such as polyester fiber for one or both of the melamine resin-impregnated fiber base materials on both surfaces is measured by JIS K 6902. ..

しかしながら、特許文献１及び特許文献２に記載されているＪＩＳ Ｋ ６９０２の曲げ成形性試験（Ａ法）では、Ｖ字形の溝が形成された治具上に配置した試験体を、溝の上方から押して折り曲げているため、試験体の屈曲する部分が一箇所となり、二次元的な曲げが判断できるだけであって、実用的に求められる三次元的な曲げに対して判断することができなかった。 However, in the bending formability test (method A) of JIS K 6902 described in Patent Document 1 and Patent Document 2, the test piece placed on the jig in which the V-shaped groove is formed is placed from above the groove. Since the test piece is pushed and bent, the bent portion of the test piece is only one place, and only two-dimensional bending can be judged, and it is not possible to judge practically required three-dimensional bending.

特開２０１４−２０８４５３号公報Japanese Unexamined Patent Publication No. 2014-208453 特開平０７−２６６４９７号公報Japanese Unexamined Patent Publication No. 07-266497

本発明は前記の点に鑑みなされたものであって、不燃性に優れ、かつ三次元的な曲げ形状の賦形が良好で、かつ軽量な炭素繊維複合化粧板の提供を目的とする。 The present invention has been made in view of the above points, and an object of the present invention is to provide a lightweight carbon fiber composite decorative board having excellent nonflammability, good shaping of a three-dimensional bent shape, and light weight.

請求項１の発明は、芯材と、前記芯材の両面に積層された繊維補強材と、前記両面の繊維補強材の少なくとも一方の繊維補強材の表面に積層された面材とからなる炭素繊維複合化粧板において、前記芯材は、連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸して前記メラミン樹脂発泡体の圧縮状態で前記フェノール樹脂が硬化したものであり、前記繊維補強材は、炭素繊維織物にフェノール樹脂が含浸硬化したものからなり、前記面材は、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布であり、前記芯材は一つの層を形成しており、前記芯材と前記繊維補強材と前記面材は、前記芯材のメラミン樹脂発泡体に含浸したフェノール樹脂と、前記繊維補強材の炭素繊維織物に含浸したフェノール樹脂の硬化によって接着しており、樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００で規定される樹脂比率が４０〜７０％であることを特徴とする。なお、請求項１の発明は、上記式で示される樹脂比率を４０〜７０％とするフェノール樹脂を接着剤として、圧縮成形時に積層部材が一体に賦形加工される炭素繊維複合化粧板である。この一体に賦形加工される際に、上記メラミン樹脂発泡体からなる芯材が圧縮されるとともに前記フェノール樹脂である接着剤が前記芯材との接着層を形成する工程を含み、かつ、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布である面材も前記接着剤が積層硬化して接着層を形成する工程を含むものである。すなわち、上記複数の工程を経た一体成形品では、メラミン樹脂発泡体が圧縮された芯材となって一層を形成する。成形後においては、フェノール樹脂を含浸した上記メラミン樹脂発泡体からなる接着剤を供給する層としての芯材は、もはやその機能を果たしており、請求項１の発明である一体成形品をその成形後の構造で表現したとしても、かかる機能を表現することができない。したがって、請求項１の発明は、その構造又は特性により直接特定することが不可能であり、重合組成物を得るためのプロセス（製法）によって初めて特定することが可能なものである。 The invention of claim 1 is a carbon composed of a core material, a fiber reinforcing material laminated on both sides of the core material, and a face material laminated on the surface of at least one of the fiber reinforcing materials on both sides. In the fiber composite decorative board, the core material is a melamine resin foam having open cells impregnated with a phenol resin, and the phenol resin is cured in a compressed state of the melamine resin foam. The face material is a woven fabric made of heat-resistant long fiber yarn coated with a fluororesin, and the core material forms one layer. The core material, the fiber reinforcing material, and the face material are adhered by curing the phenol resin impregnated in the melamine resin foam of the core material and the phenol resin impregnated in the carbon fiber woven fabric of the fiber reinforcing material. , Resin ratio = {(weight of melamine resin foam + weight of phenol resin in carbon fiber composite veneer) ÷ (weight of carbon fiber composite veneer excluding face material weight)} × 100 Is 40 to 70%. The invention of claim 1 is a carbon fiber composite decorative board in which a laminated member is integrally shaped at the time of compression molding using a phenol resin having a resin ratio of 40 to 70% represented by the above formula as an adhesive. .. When the integral shaping process is performed, the core material made of the melamine resin foam is compressed, and the adhesive which is a phenol resin includes a step of forming an adhesive layer with the core material, and fluorine. A face material, which is a woven fabric made of heat-resistant long fiber yarn coated with a resin, also includes a step of laminating and curing the adhesive to form an adhesive layer. That is, in the integrally molded product that has undergone the above-mentioned plurality of steps, the melamine resin foam becomes a compressed core material to form one layer. After molding, the core material as a layer for supplying the adhesive made of the melamine resin foam impregnated with the phenol resin has already fulfilled its function, and after the integrally molded product according to claim 1 is molded. Even if it is expressed by the structure of, such a function cannot be expressed. Therefore, the invention of claim 1 cannot be directly specified by its structure or characteristics, and can be specified only by a process (manufacturing method) for obtaining a polymerization composition.

請求項２の発明は、請求項１において、前記芯材の両面に積層された前記繊維補強材のすべての積層枚数は、２枚〜１０枚であることを特徴とする。 The invention of claim 2 is characterized in that, in claim 1, the total number of laminated fibers of the fiber reinforcing material laminated on both sides of the core material is 2 to 10.

請求項３の発明は、請求項１または２において、前記炭素繊維複合化粧板の破壊荷重（ＪＩＳ Ｋ７０７４準拠）は１００Ｎ以上８５０Ｎ以下であり、比重（ＪＩＳ Ｋ７１１２準拠）は０．５０〜１．１０であることを特徴とする。 According to the first or second aspect of the present invention, the breaking load (JIS K7074 compliant) of the carbon fiber composite decorative board is 100 N or more and 850 N or less, and the specific gravity (JIS K7112 compliant) is 0.50 to 1.10. It is characterized by being.

請求項４の発明は、請求項１から３の何れか一項において、前記炭素繊維複合化粧板には三次元的に賦形された賦形部を有し、前記賦形部の凸部又は凹部の頂部における曲率半径が３ｍｍ以上であることを特徴とする。 In the invention of claim 4, in any one of claims 1 to 3, the carbon fiber composite decorative board has a three-dimensionally shaped shaping portion, and the convex portion of the shaping portion or the convex portion of the shaping portion. The radius of curvature at the top of the recess is 3 mm or more.

請求項５の発明は、請求項１から４の何れか一項において、鉄道車両用材料燃焼性試験（国土交通省令第１５１号に準拠した試験）に不燃合格することを特徴とする。 The invention of claim 5 is characterized in that, in any one of claims 1 to 4, it passes the material combustibility test for railway vehicles (test according to the Ordinance No. 151 of the Ministry of Land, Infrastructure, Transport and Tourism) incombustible.

請求項６の発明は、連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸し、前記メラミン樹脂発泡体が圧縮された状態で前記フェノール樹脂が硬化した芯材と、炭素繊維織物にフェノール樹脂が含浸硬化した繊維補強材と、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布で構成された面材とよりなって、前記芯材の両面には前記繊維補強材が一枚以上積層され、前記両面の繊維補強材の少なくとも一方の繊維補強材の表面には前記面材が積層され、前記芯材と前記繊維補強材と前記面材が積層一体化している炭素繊維複合化粧板の製造方法であって、連続気泡を有するメラミン樹脂発泡体と炭素繊維織物の何れか一方または両方にフェノール樹脂を、樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００で規定される樹脂比率が４０〜７０％の範囲となるように含浸させる含浸工程と、前記含浸工程後に前記メラミン樹脂発泡体の両面に、それぞれ前記炭素繊維織物を複数積層配置し、前記メラミン樹脂発泡体の両面に積層配置された炭素繊維織物の少なくとも一方の炭素繊維織物に面材を積層する積層工程と、前記積層工程で得られた積層体を金型で深絞り成形して三次元的に賦形すると共に、前記積層体を圧縮状態で加熱して前記フェノール樹脂を硬化させ、前記フェノール樹脂の硬化によって前記メラミン樹脂発泡体と前記炭素繊維織物と前記面材を一体化させる深絞り成形工程と、を行うことを特徴とする。 In the invention of claim 6, a melamine resin foam having open cells is impregnated with a phenol resin, and the phenol resin is cured in a state where the melamine resin foam is compressed, and a phenol resin is formed on a carbon fiber woven fabric. A face material composed of an impregnated and cured fiber reinforcing material and a woven fabric made of heat-resistant long fiber yarn coated with fluororesin, and one or more of the fiber reinforcing materials are laminated on both sides of the core material. A carbon fiber composite decorative board in which the face material is laminated on the surface of at least one of the fiber reinforcing materials on both sides, and the core material, the fiber reinforcing material, and the face material are laminated and integrated. In the manufacturing method, phenol resin is applied to either or both of the melamine resin foam having open cells and the carbon fiber woven fabric, and the resin ratio = {(weight of melamine resin foam + phenol resin in carbon fiber composite veneer). The impregnation step of impregnating the resin so that the resin ratio defined by (weight) ÷ (weight of the carbon fiber composite veneer excluding the weight of the face material)} × 100 is in the range of 40 to 70%, and after the impregnation step, the above. A laminating step of laminating a plurality of the carbon fiber woven fabrics on both sides of the melamine resin foam and laminating a face material on at least one of the carbon fiber woven fabrics laminated on both sides of the melamine resin foam. The laminate obtained in the lamination step is deeply drawn with a mold to form it three-dimensionally, and the laminate is heated in a compressed state to cure the phenol resin, thereby curing the phenol resin. It is characterized in that a deep drawing molding step of integrating the melamine resin foam, the carbon fiber woven fabric, and the face material is performed.

炭素繊維複合化粧板に関する本発明は、芯材が、連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸してメラミン樹脂発泡体の圧縮状態でフェノール樹脂が硬化したもので芯材を構成し、芯材に積層された繊維補強材を炭素繊維織物にフェノール樹脂が含浸硬化したもので構成し、繊維補強材に積層された面材をフッ素樹脂で被覆された耐熱性長繊維糸からなる織布で構成し、樹脂比率が４０〜７０％としたことにより、鉄道車両用材料燃焼性試験に不燃合格でき、かつ三次元的な曲げ形状の賦形が良好で、軽量なものにできる。したがって、難燃剤を添加したり、金属部材を使用するといった手段を用いることがなく、不燃合格している。 In the present invention relating to a carbon fiber composite decorative board, the core material is composed of a melamine resin foam having open cells impregnated with a phenol resin and the phenol resin cured in a compressed state of the melamine resin foam. A woven fabric made of heat-resistant long-fiber yarn in which a fiber reinforcing material laminated on a core material is made of a carbon fiber woven fabric impregnated with phenol resin and cured, and a face material laminated on the fiber reinforcing material is coated with a fluororesin. By setting the resin ratio to 40 to 70%, it is possible to pass the material flammability test for railway vehicles incombustible, and the shape of the three-dimensional bent shape is good, and it can be made lightweight. Therefore, it has passed the non-combustibility without adding a flame retardant or using a metal member.

炭素繊維複合化粧板の製造方法に関する本発明は、鉄道車両用材料燃焼性試験に不燃合格でき、かつ三次元的な曲げ形状の賦形が良好で、軽量な炭素繊維複合化粧板を製造することができる。 The present invention relating to a method for manufacturing a carbon fiber composite veneer is to manufacture a lightweight carbon fiber composite veneer that can pass a non-combustible material combustibility test for railroad vehicles, has a good three-dimensional bending shape, and is lightweight. Can be done.

本発明における炭素繊維複合化粧板の第１実施形態の部分斜視図である。It is a partial perspective view of the 1st Embodiment of the carbon fiber composite decorative board in this invention. 本発明における炭素繊維複合化粧板の第２実施形態の部分斜視図である。It is a partial perspective view of the 2nd Embodiment of the carbon fiber composite decorative board in this invention. 本発明における第１実施形態及び第２実施形態の一部の断面図である。It is sectional drawing of a part of 1st Embodiment and 2nd Embodiment in this invention. 本発明における製造方法の一実施形態の工程を示す図である。It is a figure which shows the process of one Embodiment of the manufacturing method in this invention. 実施例及び比較例の構成と外観、弾性率、破壊荷重、燃焼性試験及び比重の結果を示す表である。It is a table which shows the composition and appearance, elastic modulus, fracture load, flammability test and the result of specific gravity of an Example and a comparative example.

以下、本発明の炭素繊維複合化粧板及びその製造方法について図面を用いて説明する。
図１に示す本発明の第１実施形態に係る炭素繊維複合化粧板１０Ａは、図３に示すように芯材１１と、前記芯材１１の両面に積層一体化された２層の繊維補強材２１、２１と、最外層の繊維補強材２１の表面に積層一体化された面材３１とよりなり、三次元的に賦形された賦形部１１Ａを有する。前記賦形部１１Ａは、凸形状側が意匠面側（図１参照）とされ、反対の凹形状側が裏面側となっている。 Hereinafter, the carbon fiber composite decorative board of the present invention and a method for producing the same will be described with reference to the drawings.
As shown in FIG. 3, the carbon fiber composite decorative plate 10A according to the first embodiment of the present invention shown in FIG. 1 is a two-layer fiber reinforcing material laminated and integrated with the core material 11 on both sides of the core material 11. It is composed of 21 and 21 and a face material 31 laminated and integrated on the surface of the outermost fiber reinforcing material 21, and has a three-dimensionally shaped shape portion 11A. The convex side of the shaping portion 11A is the design surface side (see FIG. 1), and the opposite concave side is the back surface side.

図２に示す本発明の第２実施形態に係る炭素繊維複合化粧板１０Ｂは、図３に示すように芯材１１と、前記芯材１１の両面に積層一体化された２層の繊維補強材２１、２１と、最外層の繊維補強材２１の表面に積層一体化された面材３１とよりなり、三次元的に賦形された賦形部１１Ｂを有する。前記賦形部１１Ｂは、凹形状側が意匠面（図２参照）とされ、反対の凸形状側が裏面となっている。 As shown in FIG. 3, the carbon fiber composite decorative plate 10B according to the second embodiment of the present invention shown in FIG. 2 is a two-layer fiber reinforcing material laminated and integrated with the core material 11 on both sides of the core material 11. It is composed of 21 and 21 and a face material 31 laminated and integrated on the surface of the outermost fiber reinforcing material 21, and has a three-dimensionally shaped shape portion 11B. The concave side of the shaping portion 11B is a design surface (see FIG. 2), and the opposite convex side is a back surface.

前記第１実施形態の炭素繊維複合化粧板１０Ａ及び第２実施形態の炭素繊維複合化粧板１０Ｂは、鉄道車両用の部材として好適なものである。鉄道車両用の部材としては、天井材、内張り材（壁材等）、窓枠材等が挙げられる。 The carbon fiber composite decorative board 10A of the first embodiment and the carbon fiber composite decorative board 10B of the second embodiment are suitable as members for railroad vehicles. Examples of members for railway vehicles include ceiling materials, lining materials (wall materials, etc.), window frame materials, and the like.

前記芯材１１は、一層で構成されており、連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸して前記メラミン樹脂発泡体の圧縮状態でフェノール樹脂が硬化したものである。前記芯材１１は、一枚でもよく、複数枚の連続気泡を有するメラミン樹脂発泡体を積層して一層を構成しても良い。前記メラミン樹脂発泡体は樹脂単体が良好な難燃性を有するため、前記芯材１１の構成材として好適なものである。前記メラミン樹脂発泡体の圧縮前の元厚みは、前記炭素繊維複合化粧板１０Ａ、１０Ｂの厚みにより異なるが、例えば３〜５０ｍｍを挙げる。また、前記メラミン樹脂発泡体は、圧縮容易性、含浸性、軽量性、剛性の点から、圧縮前の密度が５〜１５ｋｇ／ｍ３のものが好ましい。 The core material 11 is composed of one layer, and is obtained by impregnating a melamine resin foam having open cells with a phenol resin and curing the phenol resin in a compressed state of the melamine resin foam. The core material 11 may be a single piece, or a single layer may be formed by laminating a plurality of melamine resin foams having open cells. The melamine resin foam is suitable as a constituent material of the core material 11 because the resin itself has good flame retardancy. The original thickness of the melamine resin foam before compression varies depending on the thickness of the carbon fiber composite decorative plates 10A and 10B, and examples thereof include 3 to 50 mm. The melamine resin foam preferably has a density of 5 to 15 kg / m 3 before compression from the viewpoint of ease of compression, impregnation property, light weight, and rigidity.

前記繊維補強材２１は、炭素繊維織物にフェノール樹脂が含浸して硬化したものからなる。
前記炭素繊維織物は、軽量及び強度、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および開繊糸を織って得られる上記織物などが好適である。また、前記炭素繊維織物は、フェノール樹脂の含浸及び剛性、強度の点から、繊維重さが９０〜４００ｇ／ｍ２のものが好ましい。前記繊維補強材２１を構成する炭素繊維織物は、前記芯材１１の両面にそれぞれ１層以上積層されていればよい。積層数を多くし過ぎると炭素繊維複合化粧板が重くなったり、三次元形状の良好な成形が難しくなったりするため、より好ましい積層数は２層から１０層である。また、積層数は前記芯材１１の両面で等しくするのが、前記炭素繊維複合化粧板１０の剛性、強度向上、難燃性、成形後の経時的な変形を防止する点で好ましい。 The fiber reinforcing material 21 is made of a carbon fiber woven fabric impregnated with a phenol resin and cured.
The carbon fiber woven fabric is excellent in light weight, strength, and high rigidity. In particular, a woven fabric in which the fibers are not only in one direction is preferable. The above-mentioned woven fabric obtained by weaving a triaxial weave composed of threads in three directions and an open fiber yarn is suitable. Further, the carbon fiber woven fabric preferably has a fiber weight of 90 to 400 g / m 2 from the viewpoint of impregnation with phenol resin, rigidity and strength. The carbon fiber woven fabric constituting the fiber reinforcing material 21 may be laminated with one or more layers on both sides of the core material 11. If the number of layers is too large, the carbon fiber composite decorative board becomes heavy and it becomes difficult to form a good three-dimensional shape. Therefore, the number of layers is more preferably 2 to 10. Further, it is preferable that the number of layers is the same on both sides of the core material 11 from the viewpoints of improving the rigidity and strength of the carbon fiber composite decorative board 10, flame retardancy, and preventing deformation over time after molding.

前記メラミン樹脂発泡体及び前記炭素繊維織物に含浸するフェノール樹脂は、含浸後の硬化によって前記炭素繊維複合化粧板１０の剛性及び強度、難燃性を高める。 The phenol resin impregnated in the melamine resin foam and the carbon fiber woven fabric enhances the rigidity, strength, and flame retardancy of the carbon fiber composite decorative plate 10 by curing after impregnation.

前記面材３１は、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布で構成される。
耐熱性長繊維糸は、耐熱性長繊維が糸状とされたものである。また耐熱性長繊維としては、ポリイミド繊維、芳香族系ポリアミド繊維、炭素繊維、グラファイト化繊維、耐炎化繊維などを挙げることができる。なお、耐熱性長繊維は一種類に限られず、複数種類が組み合わされてもよい。
フッ素樹脂は、ポリテトラフロロエチレン樹脂、テトラフロロエチレン−ヘキサフロロプロピレン共重合体、テトラフロロエチレン−パーフロロビニルエーテル共重合体、ポリフッ化ビニリデン、エチレン−テトラフロロエチレン共重合体、エチレン−クロロトリフロロエチレン共重合体などを挙げることができる。 The face material 31 is made of a woven fabric made of heat-resistant long fiber yarn coated with fluororesin.
The heat-resistant long fiber yarn is a yarn-like heat-resistant long fiber. Examples of the heat-resistant long fibers include polyimide fibers, aromatic polyamide fibers, carbon fibers, graphitized fibers, and flame-resistant fibers. The heat-resistant long fibers are not limited to one type, and a plurality of types may be combined.
Fluororesin is polytetrafluoroethylene resin, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluorovinyl ether copolymer, polyvinylidene fluoride, ethylene-tetrafluoroethylene copolymer, ethylene-chlorotrifluororo. Examples thereof include ethylene copolymers.

実施例として、炭素繊維複合化粧板の両側に、前記面材３１が設けられる実施形態を示したが、筐体もしくは車両等の内装材等に用いられる場合、炭素繊維複合化粧板の片側のみに設けられる実施形態（図示せず）も多くある。また、前記面材３１が炭素繊維複合化粧板の片側のみに設ける場合は、意匠面側に設けられる。 As an embodiment, the embodiment in which the face material 31 is provided on both sides of the carbon fiber composite decorative board is shown, but when used for an interior material such as a housing or a vehicle, only one side of the carbon fiber composite decorative board is used. There are also many embodiments (not shown) provided. When the face material 31 is provided on only one side of the carbon fiber composite decorative board, it is provided on the design surface side.

前記芯材１１と前記繊維補強材２１と前記面材３１は、前記芯材１１のメラミン樹脂発泡体に含浸したフェノール樹脂と、前記繊維補強材２１の炭素繊維織物に含浸したフェノール樹脂の硬化によって接着している。 The core material 11, the fiber reinforced material 21, and the face material 31 are formed by curing the phenol resin impregnated in the melamine resin foam of the core material 11 and the phenol resin impregnated in the carbon fiber woven fabric of the fiber reinforcing material 21. It is glued.

前記炭素繊維複合化粧板１０Ａ、１０Ｂに含まれるフェノール樹脂は、前記炭素繊維複合化粧板１０Ａ、１０Ｂの剛性増加、前記芯材１１と前記繊維補強材２１と前記面材３１の接着一体化、及び不燃性付与の作用がある。前記フェノール樹脂の量は、少なすぎると、剛性、接着一体性が低下するようになり、一方、多すぎると、不燃性試験に合格できないこともあり、前記面材３１の織目からフェノール樹脂が浸み出し外観不良ともなる。
フェノール樹脂は、面材を除いた前記芯材１１及び積層される前記繊維補強材２１からなる積層部分における樹脂比率が、４０〜７０％となる量が好ましい。
この樹脂比率は、以下の式で示される。樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００。 The phenolic resin contained in the carbon fiber composite decorative plates 10A and 10B increases the rigidity of the carbon fiber composite decorative plates 10A and 10B, adheres and integrates the core material 11, the fiber reinforcing material 21, and the face material 31, and It has the effect of imparting nonflammability. If the amount of the phenol resin is too small, the rigidity and the adhesive integrity will be lowered, while if it is too large, the nonflammability test may not be passed, and the phenol resin is removed from the texture of the face material 31. It also exudes and has a poor appearance.
The phenol resin is preferably in an amount such that the resin ratio in the laminated portion composed of the core material 11 excluding the face material and the fiber reinforcing material 21 to be laminated is 40 to 70%.
This resin ratio is expressed by the following formula. Resin ratio = {(weight of melamine resin foam + weight of phenol resin in carbon fiber composite veneer) ÷ (weight of carbon fiber composite veneer excluding face material weight)} × 100.

前記三次元的に賦形された賦形部１１Ａ、１１Ｂは、深絞り成形により三次元的に凸形状（炭素繊維複合化粧板１０Ａの場合）あるいは凹形状（炭素繊維複合化粧板１０Ｂの場合）に賦形されたものであり、凸部の頂部１１Ａａあるいは凹部の頂部１１Ｂｂにおける曲率半径が３ｍｍ以上で構成されている。曲率半径を３ｍｍ以上とすることにより、前記面材３１の前記賦形部１１Ａ、１１Ｂの部分に、皺や亀裂などの美観を損なう不具合を生じないようにできる。 The three-dimensionally shaped shaped portions 11A and 11B are three-dimensionally convex (in the case of carbon fiber composite decorative plate 10A) or concave (in the case of carbon fiber composite decorative plate 10B) by deep drawing molding. The radius of curvature at the top 11Aa of the convex portion or the top 11Bb of the concave portion is 3 mm or more. By setting the radius of curvature to 3 mm or more, it is possible to prevent problems such as wrinkles and cracks that spoil the aesthetic appearance from occurring in the shaped portions 11A and 11B of the face material 31.

実施形態の前記炭素繊維複合化粧板１０Ａ、１０Ｂは、一面が開口した箱状からなり、そのコーナー部(角部)が前記三次元的に賦形された賦形部１１Ａ、１１Ｂで構成されている。前記三次元的に賦形された賦形部１１Ａ、１１Ｂは、コーナー部の形状に限られず、前記炭素繊維複合化粧板で構成する部材に応じた形状とされる。例えば、平面の一部に形成した半球状の凸部や凹部などでもよい。 The carbon fiber composite decorative boards 10A and 10B of the embodiment are formed of a box shape having one side open, and the corner portions (corner portions) thereof are composed of the shaping portions 11A and 11B shaped three-dimensionally. There is. The three-dimensionally shaped shaping portions 11A and 11B are not limited to the shape of the corner portion, and have a shape corresponding to the member configured by the carbon fiber composite decorative board. For example, a hemispherical convex portion or concave portion formed on a part of a flat surface may be used.

前記炭素繊維複合化粧板１０Ａ、１０Ｂは、鉄道車両用材料燃焼性試験（鉄道車両用非金属材料）に不燃合格するものである。本発明は、鉄道車両用材料燃焼性試験のうち、省令８３条、２．旅客車、客室内張に該当し、一般旅客車、地下鉄等旅客車及び新幹線旅客車、特殊鉄道に使用できる。
また、前記炭素繊維複合化粧板１０Ａ、１０Ｂは、鉄道車両用部材としての強度を保持させるため、弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）が１０ＧＰａ以上、破壊荷重（ＪＩＳ Ｋ７０７４準拠）が１００Ｎ以上８５０Ｎ以下であるのが好ましい。かつ軽量性のために比重（ＪＩＳ Ｋ７１１２準拠）は０．５０〜１．１０程度が好ましい。すなわち、比重に対する破壊荷重である比強度を、［比強度＝破壊荷重÷比重］で計算した。比強度は、１００〜１０１５が好ましい。 The carbon fiber composite decorative plates 10A and 10B pass the material combustibility test for railway vehicles (non-metal materials for railway vehicles) incombustible. The present invention relates to Article 83 of the Ministerial Ordinance, 2. It corresponds to passenger cars and cabin linings, and can be used for general passenger cars, passenger cars such as subways, Shinkansen passenger cars, and special railways.
Further, the carbon fiber composite decorative plates 10A and 10B have an elastic modulus (JIS K7074-1988 A method) of 10 GPa or more and a breaking load (JIS K7074 compliant) of 100 N or more and 850 N in order to maintain the strength as a member for a railroad vehicle. It is preferably as follows. Moreover, the specific gravity (JIS K7112 compliant) is preferably about 0.50 to 1.10 for light weight. That is, the specific strength, which is the breaking load with respect to the specific gravity, was calculated by [specific strength = breaking load ÷ specific gravity]. The specific strength is preferably 100 to 1015.

本発明の炭素繊維複合化粧板の製造方法について説明する。炭素繊維複合化粧板の製造方法は、含浸工程、積層工程、深絞り成形工程とからなる。
含浸工程では、連続気泡を有するメラミン樹脂発泡体と炭素繊維織物の何れか一方または両方にフェノール樹脂を含浸させる。フェノール樹脂を、芯材及び繊維補強材の全体に効率的に含浸させるには、メラミン樹脂発泡体と炭素繊維織物の両方にフェノール樹脂を含浸させるのが好ましい。以下の例では、メラミン樹脂発泡体と炭素繊維織物の両方にフェノール樹脂を含浸させる場合について示す。また、使用するメラミン樹脂発泡体は、圧縮容易性、含浸性、軽量性、剛性の点から、厚み（圧縮する前の厚み）が３〜５０ｍｍ、密度（圧縮前の密度）が５〜１５ｋｇ／ｍ３のものが好ましい。 The method for producing the carbon fiber composite decorative board of the present invention will be described. The method for producing the carbon fiber composite decorative board includes an impregnation step, a laminating step, and a deep drawing molding step.
In the impregnation step, either one or both of the melamine resin foam having open cells and the carbon fiber woven fabric is impregnated with the phenol resin. In order to efficiently impregnate the entire core material and fiber reinforcing material with the phenol resin, it is preferable to impregnate both the melamine resin foam and the carbon fiber woven fabric with the phenol resin. In the following example, the case where both the melamine resin foam and the carbon fiber woven fabric are impregnated with the phenol resin is shown. The melamine resin foam used has a thickness (thickness before compression) of 3 to 50 mm and a density (density before compression) of 5 to 15 kg / from the viewpoint of ease of compression, impregnation property, light weight, and rigidity. those of m 3 is preferable.

図４に示す（４−１）のように、含浸工程は含浸工程Ａと含浸工程Ｂの２種類からなる。
含浸工程Ａでは、連続気泡を有するメラミン樹脂発泡体１１０Ａにフェノール樹脂１１０Ｂを含浸させ、含浸済みメラミン樹脂発泡体１１０Ｃを得る。
一方、含浸工程Ｂでは、炭素繊維織物２１０Ａにフェノール樹脂２１０Ｂを含浸させ、含浸済み炭素繊維織物２１０Ｃを形成する。 As shown in FIG. 4 (4-1), the impregnation step comprises two types, an impregnation step A and an impregnation step B.
In the impregnation step A, the melamine resin foam 110A having open cells is impregnated with the phenol resin 110B to obtain the impregnated melamine resin foam 110C.
On the other hand, in the impregnation step B, the carbon fiber woven fabric 210A is impregnated with the phenol resin 210B to form the impregnated carbon fiber woven fabric 210C.

前記炭繊維織物２１０Ａへのフェノール樹脂２１０Ｂの含浸作業は、前記芯材１１０Ａの両面に積層する炭素繊維織物の数に応じた枚数の炭素繊維織物に対して行う。前記含浸時のフェノール樹脂１１０Ｂ、２１０Ｂは、未硬化の液状からなる。また、含浸を容易にするため、前記フェノール樹脂１１０Ｂ、２１０Ｂは溶剤に溶かしたものが好ましく、含浸後に、含浸済みメラミン樹脂発泡体１１０Ｃ及び含浸済み炭素繊維織物２１０Ｃを、前記フェノール樹脂の硬化反応を生じない温度で乾燥させることにより、前記含浸済みメラミン樹脂発泡体１１０Ｃ及び前記含浸済み炭素繊維織物２１０Ｃから溶剤を除去する。含浸手段は、液状のフェノール樹脂を収容した槽に前記メラミン樹脂発泡体あるいは炭素繊維織物を浸ける方法、スプレーにより行う方法、ロールコータにより行う方法等、適宜の方法により行う。また、フェノール樹脂の含浸量の調節は隙間を適宜調整した二本の絞りローラーに通すことにより行う。隙間を適宜調整した二本の絞りローラーに、フェノール樹脂を含浸した連続気泡を有するメラミン樹脂発泡体及びフェノール樹脂を含浸した炭素繊維織物を通すことにより、余分なフェノール樹脂を絞り取ることができ、更に、フェノール樹脂を、連続気泡を有するメラミン樹脂発泡体及び炭素繊維織物に均一に分散させることができる。
なお、本実施例では、フェノール樹脂を溶剤に溶かした溶剤系で行ったが、フェノール樹脂を水に溶かした水溶系で行ってもよい。 The work of impregnating the charcoal fiber woven fabric 210A with the phenol resin 210B is performed on a number of carbon fiber woven fabrics corresponding to the number of carbon fiber woven fabrics laminated on both sides of the core material 110A. The phenol resins 110B and 210B at the time of impregnation are uncured liquids. Further, in order to facilitate impregnation, the phenol resins 110B and 210B are preferably dissolved in a solvent, and after impregnation, the impregnated melamine resin foam 110C and the impregnated carbon fiber woven fabric 210C are subjected to a curing reaction of the phenol resin. The solvent is removed from the impregnated melamine resin foam 110C and the impregnated carbon fiber woven fabric 210C by drying at a temperature at which it does not occur. The impregnation means is performed by an appropriate method such as a method of immersing the melamine resin foam or carbon fiber woven fabric in a tank containing a liquid phenol resin, a method of spraying, a method of using a roll coater, or the like. Further, the impregnation amount of the phenol resin is adjusted by passing it through two drawing rollers whose gaps are appropriately adjusted. Excess phenol resin can be squeezed out by passing a melamine resin foam having open cells impregnated with phenol resin and a carbon fiber woven fabric impregnated with phenol resin through two drawing rollers whose gaps are appropriately adjusted. Further, the phenol resin can be uniformly dispersed in the melamine resin foam having open cells and the carbon fiber woven fabric.
In this example, the method was carried out in a solvent system in which the phenol resin was dissolved in a solvent, but it may be carried out in a water-soluble system in which the phenol resin was dissolved in water.

前記メラミン樹脂発泡体１１０Ａへのフェノール樹脂１１０Ｂの含浸と、前記炭素繊維織物２１０Ａへのフェノール樹脂２１０Ｂの含浸は、樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００で規定される樹脂比率が、４０〜７０％となるように行われる。具体的には、含浸前のメラミン樹脂発泡体の重量、含浸前の炭素繊維織物全体（全積層数）の重量、含浸後（乾燥後）のメラミン樹脂発泡体の重量、含浸後（乾燥後）の炭素繊維織物全体（全積層数）の重量、及び面材の重量を測定し、測定値を用いて前記の樹脂比率を算出し、前記樹脂比率が４０〜７０％となるように調整して炭素繊維複合化粧板の製造を行う。なお、樹脂比率の式における炭素繊維複合化粧板中のフェノール樹脂の重量は、［面材の目付量から換算できる面材の重量を除いた含浸後（乾燥後）の炭素繊維織物全体（全積層数）重量−含浸前の炭素繊維織物全体（全積層数）の重量］によって算出することができ、また、炭素繊維複合化粧板の重量は、炭素繊維複合化粧板を計測後、面材の目付量から換算できる面材の重量を除いた重量である。 The impregnation of the melamine resin foam 110A with the phenol resin 110B and the impregnation of the carbon fiber woven fabric 210A with the phenol resin 210B have a resin ratio = {(weight of the melamine resin foam + phenol resin in the carbon fiber composite decorative board). Weight) ÷ (weight of carbon fiber composite veneer excluding face material weight)} × 100, so that the resin ratio is 40 to 70%. Specifically, the weight of the melamine resin foam before impregnation, the weight of the entire carbon fiber woven fabric before impregnation (total number of layers), the weight of the melamine resin foam after impregnation (after drying), and after impregnation (after drying). The weight of the entire carbon fiber woven fabric (total number of laminated fabrics) and the weight of the face material are measured, the resin ratio is calculated using the measured values, and the resin ratio is adjusted to be 40 to 70%. Manufactures carbon fiber composite decorative boards. In addition, the weight of the phenol resin in the carbon fiber composite decorative board in the formula of the resin ratio is [the entire carbon fiber woven fabric after impregnation (after drying) excluding the weight of the face material that can be converted from the grain amount of the face material (total lamination). Number) Weight-Weight of the entire carbon fiber woven fabric (total number of laminates) before impregnation], and the weight of the carbon fiber composite veneer can be calculated after measuring the carbon fiber composite veneer. It is the weight excluding the weight of the face material that can be converted from the amount.

図４に示す（４−２）の積層工程では、前記含浸済みメラミン樹脂発泡体１１０Ｃの両面に、前記含浸済み炭素繊維織物２１０Ｃを複数枚積層配置し、さらに最外層の前記含浸済み炭素繊維織物２１０Ｃの表面に面材３１０Ｃを積層して積層体１００Ｃとする。前記含浸済み炭素繊維織物２１０Ｃの積層枚数は、前記含浸済みメラミン樹脂発泡体１１０Ｃの両面で等しくされる。また、前記面材３１０Ｃは、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布で構成されている。前記面材３１０Ｃを、片面のみに設ける場合には、前記含浸済みメラミン樹脂発泡体１１０Ｃの片面側の含浸済み炭素繊維織物２１０Ｃの最外層の表面のみに面材３１０Ｃを積層する。前記含浸済みメラミン樹脂発泡体１１０Ｃと前記含浸済み炭素繊維織物２１０Ｃ及び前記面材３１０Ｃは、平面サイズが同サイズのものが好ましいが、異なっていている場合には、後述の深絞り成形工程後、最終的にトリミングする。 In the laminating step of (4-2) shown in FIG. 4, a plurality of impregnated carbon fiber woven fabrics 210C are laminated and arranged on both sides of the impregnated melamine resin foam 110C, and the impregnated carbon fiber woven fabric in the outermost layer is further laminated. The face material 310C is laminated on the surface of 210C to form a laminated body 100C. The number of laminated carbon fiber woven fabrics 210C is equalized on both sides of the impregnated melamine resin foam 110C. Further, the face material 310C is made of a woven fabric made of heat-resistant long fiber yarn coated with a fluororesin. When the face material 310C is provided on only one side, the face material 310C is laminated only on the outermost surface of the impregnated carbon fiber woven fabric 210C on one side of the impregnated melamine resin foam 110C. The impregnated melamine resin foam 110C, the impregnated carbon fiber woven fabric 210C, and the face material 310C preferably have the same plane size, but if they are different, after the deep drawing molding step described later, Finally trim.

図４に示す（４−３）の深絞り成形工程では、前記積層体１００Ｃをプレス成形用金型の下型４１と上型４３により、深絞り成形して三次元的に賦形すると共に、圧縮して加熱する。前記下型４１には、深絞り成形用凹部４２が形成されている。また、前記上型４３には、前記下型４１の深絞り成形用凹部４２と対向する深絞り成形用凸部４４が形成されている。なお、前記下型４１の型面で賦形される面が意匠面となる場合（第１実施形態の炭素繊維複合化粧板１０Ａの場合）には、前記下型４１の深絞り成形用凹部４２は、頂部の曲率半径が３ｍｍ以上に設定される。一方、前記上型４３の型面で賦形される面が意匠面となる場合（第２実施形態の炭素繊維複合化粧板１０Ｂの場合）には、前記上型４３の深絞り成形用凸部４４は、頂部の曲率半径が３ｍｍ以上に設定される。 In the deep drawing step of (4-3) shown in FIG. 4, the laminated body 100C is deep drawn by the lower die 41 and the upper die 43 of the press molding die to form three-dimensionally. Compress and heat. The lower mold 41 is formed with a recess 42 for deep drawing. Further, the upper mold 43 is formed with a deep drawing molding convex portion 44 facing the deep drawing molding concave portion 42 of the lower mold 41. When the surface formed by the mold surface of the lower mold 41 is the design surface (in the case of the carbon fiber composite decorative plate 10A of the first embodiment), the deep drawing molding recess 42 of the lower mold 41 Is set so that the radius of curvature of the top is 3 mm or more. On the other hand, when the surface formed by the mold surface of the upper mold 43 is the design surface (in the case of the carbon fiber composite decorative plate 10B of the second embodiment), the convex portion for deep drawing molding of the upper mold 43. In 44, the radius of curvature of the top is set to 3 mm or more.

前記深絞り成形工程における圧縮率は、２００〜１５００％、特に好ましくは３００〜１０００％となるようにする。なお、圧縮率は、｛（圧縮前のメラミン樹脂発泡体の厚み−芯材の厚み）÷芯材の厚み｝×１００で規定される。芯材の厚みは、製造された炭素繊維複合化粧板における芯材の厚みである。
なお、前記下型４１と上型４３間の間隔を変化させて炭素繊維複合化粧板を実際に製造し、得られた炭素繊維複合化粧板から圧縮率を計算して目的の圧縮率となる前記下型４１と上型４３間の間隔を見つけておく。前記深絞り成形工程時、前記下型４１と上型４３間には適宜の位置にスペーサを設置して、前記下型４１と上型４３間が所定間隔（積層体の所定圧縮厚み）となるようにする。
また、加熱方法は特に限定されないが、前記下型４１と上型４３にヒーター等の加熱手段を設けて、前記下型４１と上型４３を介して行うのが簡単である。加熱温度は、含浸しているフェノール樹脂の硬化反応温度以上とされる。 The compression ratio in the deep drawing step is 200 to 1500%, particularly preferably 300 to 1000%. The compression ratio is defined as {(thickness of melamine resin foam before compression-thickness of core material) ÷ thickness of core material} × 100. The thickness of the core material is the thickness of the core material in the manufactured carbon fiber composite decorative board.
The carbon fiber composite veneer is actually manufactured by changing the distance between the lower die 41 and the upper die 43, and the compression rate is calculated from the obtained carbon fiber composite veneer to obtain the target compression rate. Find the distance between the lower mold 41 and the upper mold 43. During the deep drawing step, spacers are installed at appropriate positions between the lower mold 41 and the upper mold 43, and the space between the lower mold 41 and the upper mold 43 becomes a predetermined interval (predetermined compression thickness of the laminated body). To do so.
Further, the heating method is not particularly limited, but it is easy to provide a heating means such as a heater on the lower mold 41 and the upper mold 43 and perform the heating via the lower mold 41 and the upper mold 43. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated phenol resin.

前記深絞り成形工程における圧縮により、前記含浸済み炭素繊維織物２１０Ｃのフェノール樹脂と前記含浸済みメラミン樹脂発泡体１１０Ｃのフェノール樹脂が確実に接触する。そして前記深絞り成形工程における加熱により、前記含浸済みメラミン樹脂発泡体１１０Ｃのフェノール樹脂と前記含浸済み炭素繊維織物２１０Ｃのフェノール樹脂がそれぞれ硬化反応を開始し、前記積層体１００Ｃの圧縮状態、すなわち前記含浸済みメラミン樹脂発泡体１１０Ｃが圧縮された状態で硬化する。それにより、前記含浸済みメラミン樹脂発泡体１１０Ｃから前記芯材１１０が形成され、また、前記含浸済み炭素繊維織物２１０Ｃから前記繊維補強材２１０が形成され、前記芯材１１と前記繊維補強材２１と面材３１が前記フェノール樹脂の硬化により一体化する。その後、加熱圧縮を解除して前記炭素繊維複合化粧板１０を得る。 Due to the compression in the deep drawing step, the phenol resin of the impregnated carbon fiber woven fabric 210C and the phenol resin of the impregnated melamine resin foam 110C are surely in contact with each other. Then, by heating in the deep drawing step, the phenol resin of the impregnated melamine resin foam 110C and the phenol resin of the impregnated carbon fiber woven fabric 210C each start a curing reaction, and the compressed state of the laminate 100C, that is, the said. The impregnated melamine resin foam 110C is cured in a compressed state. As a result, the core material 110 is formed from the impregnated melamine resin foam 110C, and the fiber reinforcing material 210 is formed from the impregnated carbon fiber woven fabric 210C. The face material 31 is integrated by curing the phenol resin. After that, the heat compression is released to obtain the carbon fiber composite decorative board 10.

さらに本発明は、その課題について、面材を織布とする三次元的な曲げ形状の賦形が良好で、かつ軽量な炭素繊維複合化粧板の提供とする場合、以下のようにも表現される。すなわち、本発明の別の態様は、少なくとも一面に加飾可能な面材が積層された繊維強化成形体において、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布の面材と、前記面材の片面に積層され炭素繊維織布からなる第一の繊維補強材と、前記繊維補強材の前記面材が積層されていない面に積層される発泡体が圧縮賦形されて気泡がないメラミン樹脂層からなる芯材と、前記芯材の前記繊維補強材が積層されていない面に積層され、炭素繊維織布からなる第二の繊維補強材とからなり、
前記面材と前記第一の繊維補強材と前記芯材と前記第二の繊維補強材は、フェノール樹脂接着剤により含浸硬化されている炭素繊維複合化粧板である。
さらに、前記フェノール樹脂接着剤は、前記面材に浸みだすことなく、前記第一の繊維補強材と前記面材との間で接着層を形成する上記炭素繊維複合化粧板である。また、上記炭素繊維複合化粧板には、面材により覆われた、少なくとも３平面から形成される頂部もしくは凹部が、少なくとも一つ備えている炭素繊維複合化粧板である。 Further, the present invention is expressed as follows in the case of providing a lightweight carbon fiber composite decorative board having a good three-dimensional bending shape using a face material as a woven fabric. To. That is, another aspect of the present invention is a face material of a woven fabric made of heat-resistant long fiber yarn coated with a fluororesin in a fiber-reinforced molded body in which a face material that can be decorated is laminated on at least one surface. The first fiber reinforcing material laminated on one side of the face material and made of carbon fiber woven cloth and the foam laminated on the surface of the fiber reinforcing material on which the face material is not laminated are compression-shaped and have no air bubbles. It is composed of a core material made of a melamine resin layer and a second fiber reinforcing material made of a carbon fiber woven fabric, which is laminated on a surface of the core material where the fiber reinforcing material is not laminated.
The face material, the first fiber reinforcing material, the core material, and the second fiber reinforcing material are carbon fiber composite decorative boards impregnated and cured with a phenol resin adhesive.
Further, the phenol resin adhesive is the carbon fiber composite decorative board that forms an adhesive layer between the first fiber reinforcing material and the face material without seeping into the face material. Further, the carbon fiber composite decorative board is a carbon fiber composite decorative board provided with at least one top or recess formed from at least three planes covered with a face material.

フェノール樹脂は、住友ベークライト株式会社製、品名；ＰＲ−５５７９１Ｂ、樹脂濃度６０ｗｔ％エタノール溶液を用いた。このフェノール樹脂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時間乾燥させて含浸済み炭素繊維織物を、図５の表に示す各実施例及び各比較例の繊維補強材の積層枚数に応じて形成した。なお、図５の表における［繊維補強材の積層枚数］は、表裏均等に配列した、成形体の総積層枚数である。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、厚み０．２３ｍｍ）を使用した。乾燥後の含浸済み炭素繊維織物は、１枚当たり２２ｇであった。なお、含浸量の調節は、フェノール樹脂から取り出した炭素繊維織物を、隙間を調整した二本の絞りローラーに通すことにより行った。 As the phenol resin, a product name; PR-55791B manufactured by Sumitomo Bakelite Co., Ltd., and an ethanol solution having a resin concentration of 60 wt% was used. A plain weave carbon fiber woven fabric (manufactured by Toho Tex Co., Ltd., product name; W-3101, fiber weight 200 g / m 2 ) is dipped in this phenol resin, taken out, and naturally dried at room temperature at 25 ° C. for 2 hours, and further 60 The impregnated carbon fiber woven fabric was dried in an atmosphere of ° C. for 1 hour to form an impregnated carbon fiber woven fabric according to the number of laminated fiber reinforcing materials of each Example and each Comparative Example shown in the table of FIG. The [number of laminated fiber reinforcing materials] in the table of FIG. 5 is the total number of laminated molded bodies arranged evenly on the front and back sides. As the carbon fiber woven fabric, one cut into a flat size of 200 × 300 mm (weight 12 g / sheet, thickness 0.23 mm) was used. The amount of the impregnated carbon fiber woven fabric after drying was 22 g per sheet. The impregnation amount was adjusted by passing the carbon fiber woven fabric taken out from the phenol resin through two drawing rollers having adjusted gaps.

また、厚みを５ｍｍとした連続気泡を有するメラミン樹脂発泡体（ＢＡＳＦ社製、品名：バソテクトＧ、密度９ｋｇ／ｍ３）を、平面サイズ２００×３００ｍｍに切り出し、前記炭素繊維織物と同様にしてフェノール樹脂溶液に漬け、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時間乾燥させて含浸済みメラミン樹脂発泡体を形成した。
フッ素樹脂で被覆された耐熱性長繊維糸からなる織布からなる面材として、株式会社Ｉ．Ｓ．Ｔ製、イストフロン不燃クロスを用いた。
含浸前のメラミン樹脂発泡体の重量、含浸前の炭素繊維織物全体（全積層数）の重量、含浸後（乾燥後）のメラミン樹脂発泡体の重量、含浸後（乾燥後）の炭素繊維織物全体（全積層数）の重量、及び面材の重量を測定し、測定値を用いて計算した樹脂比率を図５の表に示す。 Further, a melamine resin foam having open cells having a thickness of 5 mm (manufactured by BASF, product name: Basotect G, density 9 kg / m 3 ) was cut into a plane size of 200 × 300 mm, and phenol was formed in the same manner as the carbon fiber woven fabric. After being immersed in a resin solution and taken out, it was naturally dried at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to form an impregnated melamine resin foam.
As a face material made of a woven fabric made of heat-resistant long fiber yarn coated with fluororesin, I.I. S. Istoflon non-combustible cloth made by T was used.
Weight of melamine resin foam before impregnation, weight of total carbon fiber woven fabric before impregnation (total number of layers), weight of melamine resin foam after impregnation (after drying), total carbon fiber woven fabric after impregnation (after drying) The weight of (total number of laminated fabrics) and the weight of the face material are measured, and the resin ratio calculated using the measured values is shown in the table of FIG.

次に、予め離型剤を表面に塗布した鉄製のプレス成形用の金型として、頂部の曲率半径が３ｍｍ（比較例４では曲率半径１．５ｍｍ）からなる三次元形状の深絞り成形用凹部を四隅に有する凹形状の型面を有する下型と、該下型に対応した上型を用い、含浸後（乾燥後）のメラミン樹脂発泡体と、含浸後（乾燥後）炭素繊維織物と、面材とを、図４の（４−３）のように積層した状態で、下型と上型により深絞り成形した。深絞り成形は、前記積層体を下型と上型により、１５０℃で１０分間、１０ＭＰａの面圧をかけて押圧し、圧縮して三次元的に賦形すると共に加熱を行ない、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、下型及び上型に取り付けられた鋳込みヒーターにより行なった。また、下型と上型間には、図５の表に示す［製品板厚］と等しい厚みの鉄製スペーサを介在させて下型と上型間の間隔、すなわち積層体の圧縮厚みを調整した。その後、下型と上型を開き、芯材の両面に繊維補強材と面材が積層一体化した各実施例及び各比較例の炭素繊維複合化粧板を得た。得られた炭素繊維複合化粧板は、一面が開口した箱状（深さ１０ｍｍ×縦１５０×横２５０ｍｍ）であり、四隅に三次元的に賦形された賦形部（深絞り成形部）を有する。 Next, as an iron press-molding die in which a mold release agent is previously applied to the surface, a three-dimensional deep-drawing concave portion having a radius of curvature of 3 mm at the top (radius of curvature of 1.5 mm in Comparative Example 4). Using a lower mold having concave mold surfaces at the four corners and an upper mold corresponding to the lower mold, a melamine resin foam after impregnation (after drying), a carbon fiber woven fabric after impregnation (after drying), and The face materials were deep-drawn by a lower die and an upper die in a state of being laminated as shown in (4-3) of FIG. In deep drawing, the laminate is pressed by a lower mold and an upper mold at 150 ° C. for 10 minutes with a surface pressure of 10 MPa, compressed, three-dimensionally shaped, and heated. The phenol resin was reactively cured in. The heating at that time was performed by the cast heater attached to the lower mold and the upper mold. Further, an iron spacer having a thickness equal to the [product plate thickness] shown in the table of FIG. 5 was interposed between the lower mold and the upper mold to adjust the distance between the lower mold and the upper mold, that is, the compression thickness of the laminated body. .. Then, the lower mold and the upper mold were opened to obtain carbon fiber composite decorative plates of Examples and Comparative Examples in which the fiber reinforcing material and the face material were laminated and integrated on both sides of the core material. The obtained carbon fiber composite veneer has a box shape (depth 10 mm × length 150 × width 250 mm) with one side open, and three-dimensionally shaped shaped portions (deep drawing molded portions) are formed at the four corners. Have.

各実施例及び各比較例について、繊維補強材比率（％）と前記圧縮率（％）を計算した。補強材比率（％）は、前記炭素繊維複合化粧板に対する繊維補強材全体の厚みの割合（％）である。
各実施例及び各比較例の炭素繊維複合化粧板について、金型の曲率半径３．０ｍｍで賦形された賦形部（深絞り成形部）の外観の目視観察、厚み（製品板厚）、比重（ＪＩＳ Ｋ７１１２準拠）、曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）、破壊荷重（ＪＩＳ Ｋ７０７４準拠）の測定、鉄道車両用材料燃焼性試験を行った。測定結果は図５の表に示す。 For each Example and each Comparative Example, the fiber reinforced material ratio (%) and the compression ratio (%) were calculated. The reinforcing material ratio (%) is the ratio (%) of the total thickness of the fiber reinforcing material to the carbon fiber composite decorative board.
For the carbon fiber composite decorative plates of each example and each comparative example, visual observation of the appearance of the shaped portion (deep drawing molded portion) shaped with a radius of curvature of 3.0 mm of the mold, thickness (product plate thickness), Specific gravity (JIS K7112 compliant), flexural modulus (JIS K7074-1988 A method), fracture load (JIS K7074 compliant) were measured, and material flammability test for railway vehicles was performed. The measurement results are shown in the table of FIG.

外観の目視観察では、炭素繊維複合化粧板の賦形部（深絞り成形部）を含む外面及び内面の外観に対して、皺、亀裂、フェノール樹脂の染み出しの有無を判断した。
炭素繊維複合化粧板の厚み（製品板厚）は平面部の厚みをデジタルマイクロメーターにより測定した。炭素繊維複合化粧板の厚み（製品板厚）は、前記プレス成形用下型と上型間の間隔と等しかった。
鉄道車両用材料燃焼性試験は、平成２８年度新方式に従って行った。 In the visual observation of the appearance, the presence or absence of wrinkles, cracks, and exudation of phenol resin was determined with respect to the appearance of the outer surface and the inner surface including the shaped portion (deep drawing molded portion) of the carbon fiber composite decorative board.
The thickness of the carbon fiber composite decorative board (product board thickness) was measured by measuring the thickness of the flat surface portion with a digital micrometer. The thickness of the carbon fiber composite decorative board (product board thickness) was equal to the distance between the lower die and the upper die for press molding.
The material flammability test for railway vehicles was conducted according to the new method in 2016.

実施例１は、炭素繊維複合化粧板の板厚が２ｍｍ、芯材両面各々の繊維補強材の積層枚数が２枚、表裏合計４枚、繊維補強材比率が４６．０％、圧縮率３６３％、樹脂比率６０．０％、金型の曲率半径が３．０ｍｍであり、賦形部（深絞り成形部）の外観問題無し、弾性率２０ＧＰａ、破壊荷重２１０Ｎ、燃焼性試験が不燃合格、比重が０．８１であった。 In Example 1, the thickness of the carbon fiber composite decorative board is 2 mm, the number of laminated fiber reinforcing materials on both sides of the core material is 2, the total number of front and back surfaces is 4, the fiber reinforcing material ratio is 46.0%, and the compression modulus is 363%. , Resin ratio 60.0%, radius of curvature of mold is 3.0mm, there is no problem in appearance of shaping part (deep drawing molded part), elastic modulus 20GPa, breaking load 210N, flammability test passed non-combustibility, specific gravity Was 0.81.

実施例２は、樹脂比率が６８．０％である点を除き、他は実施例１と同様の製造条件であり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率２４ＧＰａ、破壊荷重２３０Ｎ、燃焼性試験が不燃合格、比重が１．０８であった。 Example 2 has the same manufacturing conditions as in Example 1 except that the resin ratio is 68.0%, and the measurement result shows that there is no problem in the appearance of the shaped portion (deep drawing molded portion) and the elastic modulus. It was 24 GPa, a breaking load of 230 N, a flammability test passed non-combustibility, and a specific gravity of 1.08.

実施例３は、樹脂比率が４２．９％である点を除き、他は実施例１と同様の製造条件であり、測定結果は賦形部（絞り部深絞り成形部）の外観問題無し、弾性率１５ＧＰａ、破壊荷重１７０Ｎ、燃焼性試験が不燃合格、比重が０．６０であった。 Example 3 has the same manufacturing conditions as in Example 1 except that the resin ratio is 42.9%, and the measurement result shows that there is no problem in the appearance of the shaping portion (throttle portion deep drawing molded portion). The elastic modulus was 15 GPa, the breaking load was 170 N, the flammability test passed non-combustibility, and the specific gravity was 0.60.

実施例４は、炭素繊維複合化粧板の板厚が３ｍｍ、芯材両面各々の繊維補強材の積層枚数が２枚、表裏合計４枚、繊維補強材比率３０．７％、圧縮率３８１％、樹脂比率６６．７％、金型の曲率半径が３．０ｍｍであり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率１７ＧＰａ、破壊荷重１８０Ｎ、燃焼性試験が不燃合格、比重が０．６５であった。 In Example 4, the thickness of the carbon fiber composite decorative board was 3 mm, the number of laminated fiber reinforcing materials on both sides of the core material was 2, a total of 4 on the front and back, the fiber reinforcing material ratio was 30.7%, and the compression modulus was 381%. The resin ratio is 66.7%, the radius of curvature of the mold is 3.0 mm, the measurement results show that there is no problem with the appearance of the shaping part (deep drawing part), the elastic modulus is 17 GPa, the breaking load is 180 N, and the flammability test passes non-combustibility. , The specific gravity was 0.65.

実施例５は、炭素繊維複合化粧板の板厚が３ｍｍ、芯材両面各々の繊維補強材の積層枚数が５枚、表裏合計１０枚、繊維補強材比率７６．７％、圧縮率６１４％、樹脂比率４４．４％、金型の曲率半径が３．０ｍｍであり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率２５ＧＰａ、破壊荷重５２０Ｎ、燃焼性試験が不燃合格、比重が０．９８であった。 In Example 5, the thickness of the carbon fiber composite decorative board is 3 mm, the number of laminated fiber reinforcing materials on both sides of the core material is 5, the total number of front and back surfaces is 10, the fiber reinforcing material ratio is 76.7%, and the compression coefficient is 614%. The resin ratio is 44.4%, the radius of curvature of the mold is 3.0 mm, the measurement results show that there is no problem with the appearance of the shaping part (deep drawing part), the elastic modulus is 25 GPa, the breaking load is 520 N, and the flammability test passes non-combustibility. , The specific gravity was 0.98.

実施例６は、炭素繊維複合化粧板の板厚が３ｍｍ、芯材両面各々の繊維補強材の積層枚数が３枚、表裏合計６枚、繊維補強材比率４６．０％、圧縮率２０９％、樹脂比率６０．０％、金型の曲率半径が３．０ｍｍであり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率１８ＧＰａ、破壊荷重３００Ｎ、燃焼性試験が不燃合格、比重が０．８１であった。 In Example 6, the thickness of the carbon fiber composite veneer was 3 mm, the number of laminated fiber reinforcing materials on both sides of the core material was 3, a total of 6 on the front and back, the fiber reinforcing material ratio was 46.0%, and the compression modulus was 209%. The resin ratio is 60.0%, the radius of curvature of the mold is 3.0 mm, the measurement results show that there is no problem with the appearance of the shaping part (deep drawing part), the elastic modulus is 18 GPa, the breaking load is 300 N, and the flammability test passes non-combustibility. , The specific gravity was 0.81.

実施例７は、炭素繊維複合化粧板の板厚が５ｍｍ、芯材両面各々の繊維補強材の積層枚数が５枚、表裏合計１０枚、繊維補強材比率４６．０％、圧縮率２７０％、樹脂比率６０．０％、金型の曲率半径が３．０ｍｍであり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率２０ＧＰａ、破壊荷重８４０Ｎ、燃焼性試験が不燃合格、比重が０．８３であった。 In Example 7, the thickness of the carbon fiber composite decorative board is 5 mm, the number of laminated fiber reinforcing materials on both sides of the core material is 5, the total number of front and back surfaces is 10, the fiber reinforcing material ratio is 46.0%, and the compression coefficient is 270%. The resin ratio is 60.0%, the radius of curvature of the mold is 3.0 mm, the measurement results show that there is no problem with the appearance of the shaping part (deep drawing part), the elastic modulus is 20 GPa, the breaking load is 840 N, and the flammability test passes non-combustibility. , The specific gravity was 0.83.

実施例８は、炭素繊維複合化粧板の板厚が１ｍｍ、芯材両面各々の繊維補強材の積層枚数が１枚、表裏合計２枚、繊維補強材比率４６．０％、圧縮率８２６％、樹脂比率６６．７％、金型の曲率半径が３．０ｍｍであり、測定結果は賦形部（深絞り成形部）の外観問題無し、弾性率２０ＧＰａ、破壊荷重１１０Ｎ、燃焼性試験が不燃合格、比重が１．０６であった。 In Example 8, the thickness of the carbon fiber composite decorative board is 1 mm, the number of laminated fiber reinforcing materials on both sides of the core material is 1, the total number of front and back surfaces is 2, the fiber reinforcing material ratio is 46.0%, and the compression coefficient is 826%. The resin ratio is 66.7%, the radius of curvature of the mold is 3.0 mm, the measurement results show that there is no problem with the appearance of the shaping part (deep drawing part), the elastic modulus is 20 GPa, the breaking load is 110 N, and the flammability test passes non-combustibility. , The specific gravity was 1.06.

このように、実施例１〜８の炭素繊維複合化粧板は、何れも不燃試験に合格し、かつ賦形部（深絞り成形部）において外観が良好であると共に、比重が０．６０〜１．０８で軽量なものであった。なお、金型の曲率半径が３ｍｍより大の場合の例については示していないが、金型の曲率半径が大になれば、皺や破れなどが生じ難くなるのは周知であり、実施例１〜８において、金型の曲率半径を３ｍｍ以上としても得られる炭素繊維複合化粧板は、賦形部（深絞り成形部）において外観が良好なものになる。 As described above, all of the carbon fiber composite decorative boards of Examples 1 to 8 have passed the non-combustibility test, have a good appearance in the shaping portion (deep drawing molded portion), and have a specific gravity of 0.60 to 1. It was .08 and lightweight. Although an example in which the radius of curvature of the mold is larger than 3 mm is not shown, it is well known that if the radius of curvature of the mold is larger, wrinkles and tears are less likely to occur. In 8 to 8, the carbon fiber composite decorative plate obtained even if the radius of curvature of the mold is 3 mm or more has a good appearance in the shaping portion (deep drawing molded portion).

比較例１は、樹脂比率が７１．４％である以外は、実施例１と同様の条件で製造されたものであり、測定結果は賦形部（深絞り成形部）で面材に樹脂が染み出しており、外観不良であった。なお外観不良であったため、他の試験項目については試験を行わなかった。 Comparative Example 1 was manufactured under the same conditions as in Example 1 except that the resin ratio was 71.4%, and the measurement result was that the face material had resin in the shaping part (deep drawing part). It had exuded and had a poor appearance. Since the appearance was poor, no tests were conducted on other test items.

比較例２は、樹脂比率が３８．４％である以外は、実施例１と同様の条件で製造されたものであり、測定結果は賦形部（深絞り成形部）で面材に樹脂が染み出しており、外観不良であった。なお外観不良であったため、他の試験項目については試験を行わなかった。 Comparative Example 2 was manufactured under the same conditions as in Example 1 except that the resin ratio was 38.4%, and the measurement result was that the face material had resin in the shaping part (deep drawing part). It had exuded and had a poor appearance. Since the appearance was poor, no tests were conducted on other test items.

比較例３は、炭素繊維複合化粧板の板厚が２ｍｍ、芯材両面各々の繊維補強材の積層枚数が１枚、表裏合計２枚、繊維補強材比率が２３．０％、圧縮率２２５％、樹脂比率７１．４％、金型の曲率半径が３．０ｍｍであり、賦形部（深絞り成形部）で面材に樹脂が染み出しており、外観不良であった。なお外観不良であったため、他の試験項目については試験を行わなかった。 In Comparative Example 3, the thickness of the carbon fiber composite decorative board is 2 mm, the number of laminated fiber reinforcing materials on both sides of the core material is 1, the total number of front and back surfaces is 2, the fiber reinforcing material ratio is 23.0%, and the compression ratio is 225%. The resin ratio was 71.4%, the radius of curvature of the mold was 3.0 mm, and the resin oozes out from the face material at the shaping portion (deep drawing molding portion), resulting in a poor appearance. Since the appearance was poor, no tests were conducted on other test items.

比較例１〜３は、樹脂比率が本発明の範囲を外れるものであるため、賦形部（深絞り成形部）で面材に樹脂が染み出した外観不良のものであり、車両用部材において美観が求められる部材には適さないものである。 In Comparative Examples 1 to 3, since the resin ratio is out of the range of the present invention, the resin exudes to the face material at the shaping portion (deep drawing molded portion) and has a poor appearance. It is not suitable for members that require aesthetics.

このように、本発明の炭素繊維複合化粧板は、鉄道車両用材料燃焼性試験に不燃合格でき、かつ三次元的な曲げ形状の賦形が良好で、軽量なものである。 As described above, the carbon fiber composite decorative board of the present invention can pass the material combustibility test for railroad vehicles incombustible, has a good three-dimensional bending shape, and is lightweight.

１０Ａ、１０Ｂ 炭素繊維複合化粧板
１１Ａ、１１Ｂ 三次元的に賦形された賦形部
１１ 芯材
２１ 繊維補強材
３１ 面材
４１ 下型
４３ 上型
１００Ｃ 積層体
１１０Ａ メラミン樹脂発泡体
１１０Ｂ フェノール樹脂
１１０Ｃ 含浸済みメラミン樹脂発泡体
２１０Ａ 炭素繊維織物
２１０Ｂ フェノール樹脂
２１０Ｃ 含浸済み炭素繊維織物 10A, 10B Carbon fiber composite veneer 11A, 11B Three-dimensionally shaped shaped part 11 Core material 21 Fiber reinforced concrete 31 Face material 41 Lower type 43 Upper type 100C Laminated body 110A Melamine resin foam 110B Phenol formaldehyde 110C Impregnated melamine resin foam 210A carbon fiber woven fabric 210B phenol resin 210C impregnated carbon fiber woven fabric

Claims (6)

芯材と、前記芯材の両面に積層された繊維補強材と、前記両面の繊維補強材の少なくとも一方の繊維補強材の表面に積層された面材とからなる炭素繊維複合化粧板において、
前記芯材は、連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸して前記メラミン樹脂発泡体の圧縮状態で前記フェノール樹脂が硬化したものであり、
前記メラミン樹脂発泡体は、圧縮前の厚みが３〜５０ｍｍ、圧縮前の密度が５〜１５ｋｇ／ｍ ３ であり、
前記繊維補強材は、炭素繊維織物にフェノール樹脂が含浸硬化したものからなり、
前記面材は、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布であり、
前記芯材は一つの層を形成しており、
前記芯材と前記繊維補強材と前記面材は、前記芯材のメラミン樹脂発泡体に含浸したフェノール樹脂と、前記繊維補強材の炭素繊維織物に含浸したフェノール樹脂の硬化によって接着しており、
樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００で規定される樹脂比率が４０〜７０％であり、
前記炭素繊維複合化粧板には三次元的に賦形された賦形部を有することを特徴とする炭素繊維複合化粧板。 In a carbon fiber composite decorative board composed of a core material, a fiber reinforcing material laminated on both sides of the core material, and a face material laminated on the surface of at least one of the fiber reinforcing materials on both sides.
The core material is a melamine resin foam having open cells impregnated with a phenol resin, and the phenol resin is cured in a compressed state of the melamine resin foam.
The melamine resin foam has a thickness of 3 to 50 mm before compression and a density of 5 to 15 kg / m 3 before compression.
The fiber reinforcing material is made of a carbon fiber woven fabric impregnated with a phenol resin and cured.
The face material is a woven fabric made of heat-resistant long fiber yarn coated with fluororesin.
The core material forms one layer,
The core material, the fiber reinforcing material, and the face material are adhered to each other by curing the phenol resin impregnated in the melamine resin foam of the core material and the phenol resin impregnated in the carbon fiber woven fabric of the fiber reinforcing material.
Resin ratio = {(weight of melamine resin foam + weight of phenol resin in carbon fiber composite veneer) ÷ (weight of carbon fiber composite veneer excluding face material weight)} × 100 40% to 70% der is,
The carbon fiber composite veneer is characterized by having a three-dimensionally shaped portion. 前記芯材の両面に積層された前記繊維補強材のすべての積層枚数は、２枚〜１０枚であることを特徴とする請求項１に記載の炭素繊維複合化粧板。 The carbon fiber composite decorative board according to claim 1, wherein the total number of laminated fibers of the fiber reinforcing materials laminated on both sides of the core material is 2 to 10. 前記炭素繊維複合化粧板の破壊荷重（ＪＩＳ Ｋ７０７４準拠）は１００Ｎ以上８５０Ｎ以下であり、比重（ＪＩＳ Ｋ７１１２準拠）は０．５０〜１．１０である請求項１または２に記載の炭素繊維複合化粧板 The carbon fiber composite cosmetic according to claim 1 or 2, wherein the breaking load (JIS K7074 compliant) of the carbon fiber composite decorative board is 100 N or more and 850 N or less, and the specific gravity (JIS K7112 compliant) is 0.50 to 1.10. Board 前記炭素繊維複合化粧板には三次元的に賦形された賦形部を有し、前記賦形部の凸部又は凹部の頂部における曲率半径が３ｍｍ以上であることを特徴とする請求項１から３のいずれか一項に記載の炭素繊維複合化粧板。 The carbon fiber composite decorative board has a three-dimensionally shaped shaped portion, and the radius of curvature at the top of the convex portion or the concave portion of the shaped portion is 3 mm or more. The carbon fiber composite decorative board according to any one of 3 to 3. 鉄道車両用材料燃焼性試験に不燃合格す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化粧板。 The carbon fiber composite decorative board according to any one of claims 1 to 4, wherein the material combustible test for a railroad vehicle is passed incombustible. 連続気泡を有するメラミン樹脂発泡体にフェノール樹脂が含浸し、前記メラミン樹脂発泡体が圧縮された状態で前記フェノール樹脂が硬化した芯材と、炭素繊維織物にフェノール樹脂が含浸硬化した繊維補強材と、フッ素樹脂で被覆された耐熱性長繊維糸からなる織布で構成された面材とよりなって、前記芯材の両面には前記繊維補強材が一枚以上積層され、前記両面の繊維補強材の少なくとも一方の繊維補強材の表面には前記面材が積層され、前記芯材と前記繊維補強材と前記面材が積層一体化している炭素繊維複合化粧板の製造方法であって、
連続気泡を有し、圧縮前の厚みが３〜５０ｍｍ、圧縮前の密度が５〜１５ｋｇ／ｍ ３ であるメラミン樹脂発泡体と炭素繊維織物の何れか一方または両方にフェノール樹脂を、樹脂比率＝｛（メラミン樹脂発泡体の重量＋炭素繊維複合化粧板中のフェノール樹脂の重量）÷（面材の重量を除く炭素繊維複合化粧板の重量）｝×１００で規定される樹脂比率が４０〜７０％の範囲となるように含浸させる含浸工程と、
前記含浸工程後に前記メラミン樹脂発泡体の両面に、それぞれ前記炭素繊維織物を複数積層配置し、前記メラミン樹脂発泡体の両面に積層配置された炭素繊維織物の少なくとも一方の炭素繊維織物に面材を積層する積層工程と、
前記積層工程で得られた積層体を金型で深絞り成形して三次元的に賦形すると共に、前記積層体を圧縮状態で加熱して前記フェノール樹脂を硬化させ、前記フェノール樹脂の硬化によって前記メラミン樹脂発泡体と前記炭素繊維織物と前記面材を一体化させる深絞り成形工程と、
を行うことを特徴とする炭素繊維複合化粧板の製造方法。 A core material in which a melamine resin foam having open cells is impregnated with a phenol resin and the phenol resin is cured in a state where the melamine resin foam is compressed, and a fiber reinforcing material in which a carbon fiber woven fabric is impregnated with a phenol resin and cured. A face material made of a woven fabric made of heat-resistant long fiber threads coated with a fluororesin is formed, and one or more of the fiber reinforcing materials are laminated on both sides of the core material to reinforce the fibers on both sides. A method for producing a carbon fiber composite decorative board in which the face material is laminated on the surface of at least one fiber reinforcing material of the material, and the core material, the fiber reinforcing material, and the face material are laminated and integrated.
Have a continuous air bubbles, the thickness before compression is 3 to 50 mm, density before compression is either one or both the phenolic resin melamine resin foam and the carbon fiber woven fabric is 5~15kg / m 3, the resin ratio = {(Weight of melamine resin foam + Weight of phenol resin in carbon fiber composite veneer) ÷ (Weight of carbon fiber composite veneer excluding face material weight)} The resin ratio specified by x100 is 40 to 70. The impregnation process of impregnating so that it is in the range of%, and
After the impregnation step, a plurality of the carbon fiber woven fabrics are laminated on both sides of the melamine resin foam, and a face material is placed on at least one carbon fiber woven fabric of the carbon fiber woven fabrics laminated on both sides of the melamine resin foam. Laminating process and laminating
The laminate obtained in the lamination step is deep-drawn and molded with a mold to form three-dimensionally, and the laminate is heated in a compressed state to cure the phenol resin, and the phenol resin is cured. A deep drawing step of integrating the melamine resin foam, the carbon fiber woven fabric, and the face material, and
A method for producing a carbon fiber composite decorative board.
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