JP6980652B2 - 多層繊維複合体 - Google Patents
多層繊維複合体 Download PDFInfo
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- JP6980652B2 JP6980652B2 JP2018521376A JP2018521376A JP6980652B2 JP 6980652 B2 JP6980652 B2 JP 6980652B2 JP 2018521376 A JP2018521376 A JP 2018521376A JP 2018521376 A JP2018521376 A JP 2018521376A JP 6980652 B2 JP6980652 B2 JP 6980652B2
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- complex
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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Landscapes
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Description
(a)これら少なくとも3つの繊維複合体プライの各々は、エンドレス繊維を備え、
− 各プライ内のエンドレス繊維が、単方向に整列配置され、且つ
− ポリカーボネート系プラスチックの中に埋め込まれていて、ポリカーボネートが、ホモポリカーボネートまたはコポリカーボネートから選択され、
(b)内側繊維複合体プライは、実質的に同じ配向を有し、且つそれらの配向が外側繊維複合体プライを基準にして30°〜90°回転し、繊維複合体材料のプライの配向は、そのプライ内に存在する単方向に整列配置された繊維の配向によって決まる。
Vf=100×(ρt−ρc)/ρt(式1)
式中、
Vfは、サンプル中の空隙率[%];
ρcは、試験試料の密度であり、例えば、液体またはガスピクノメトリによって決まる。
ρtは、式2に従って算出される本試験試料の理論密度であり、次式
ρt=1/[Wf/ρf+Wm/ρm](式2)のとおりである。
ρmは、ポリマーマトリックスの密度(例えば、適切な結晶性);
ρfは、使用された繊維の密度;
Wfは、使用された繊維の重量分率であり、且つ
Wmは、ポリマーマトリックスの重量分率である。
多層複合体の繊維複合体プライを生成する好ましいプロセスは、特に、
エンドレス繊維バンドを提供し、エンドレス繊維バンドを処理ラインに沿って運搬する工程と、
エンドレス繊維バンドを、ポリカーボネート系プラスチックのガラス遷移温度よりも高い処理温度まで、予備加熱する工程と、
エンドレス繊維バンドの全幅にわたって、エンドレス繊維バンドの一表面上に、溶融ポリカーボネート系プラスチックを塗布する工程と、
ポリカーボネート系プラスチックの塗布後に、バンドの平面に対して垂直に、エンドレス繊維バンドに対し圧力を印加する工程であって、少なくとも1つのプレスラムを用いて圧力印加を遂行し、バンド平面内に振動運動成分を含むプレスラムに対し、且つバンドの走行方向に対して横方向へ、同時的に剪断振動を印加する工程と、
少なくとも圧力剪断振動の印加が停止するまで、エンドレス繊維バンドを、ポリカーボネート系プラスチックのガラス遷移温度を超える処理温度範囲内に保持する工程と、
を含む。
本発明は、本発明による多層複合体を生成する方法を更に提供するものであり、この方法は、下記工程を含む。
外側繊維複合体プライ同士の間に少なくとも1つの内側繊維複合体プライを導入し、内側繊維複合体プライは同じ配向を有し、且つそれらの配向が外側繊維複合体プライを基準にして30°〜90°回転する工程と、
層状の繊維複合体プライを、特に、圧力および温度を手段として結合し、多層複合体を供給する工程と、
を含む、多層複合体の生成プロセス。
電子デバイスの筐体として使用または筐体に採用するのに適した筐体パーツを生成する工程であって、
a)本発明による多層複合体を開始材料として提供する工程と、
b)更なる構成要素を形成し且つ/あるいは構成要素同士を一体的に組み立てて、筐体パーツを供給する工程と、
を実行することを含む、筐体パーツの生成工程。
線形ポリカーボネート類(主成分:ビスフェノールA)、溶融体積流量MVR6.0cm3/10min(ISO1133準拠、試験温度300°C、荷重1.2kg)。
三菱レイヨン株式会社製パイロフィルTRH50の60Mカーボン繊維は、個別のフィラメント径が7μm、密度が1.81g/cm3、および張力係数が250GPaである。60,000個の個別フィラメントが、エンドレススプールとしてロービング内に得られる。
実施例を実行/評価する目的に用いる関連パラメータを特定する方法のほか、本発明による汎用の関連パラメータを特定する方法も、本明細書中に以下詳述されている。
市販のマイクロメータを使用して、結合を遂行した後、結果として、繊維複合体プライおよび多層複合体の厚さを算出した。報告された結果は、別々の位置における5通りの個々の測定値の算術手段であった。
熱間プレスを介して先に結合しておいた本試験試料に関して上述されているように、空隙率を厚さ差分法で求めた。実際の試料厚さの算出を、当該の構成要素にわたって分散された5つの測定点で遂行した。空隙率の計算には、実際のサンプル厚さを5回にわたって個別に算出する算術手段を使用した。
プロファイラ7.21制御ソフトウェアおよびApex 3D評価ソフトウェアを用いたケーエルエー(KLA)テンコールP16+(商標)インスツルメントを使用して、表面に対する波形パラメータを算出した。
曲げ弾性率5の試験試料を配向(0°、90°)毎に算出するため、最初に生成された多層複合体シート(DiaカッティングディスクCFKファインブレードを使用したMutronic Diadisc 5200カットオフ鋸)から調製した。その後、外部マイクロメータを使用して、厳密な試料寸法(幅および厚さ)の算出を行った。ASTMD790−10法Aに準じて、本試験を実施した。結果として得られた力距離図の勾配は、曲げ弾性率に対応している。報告された結果は、5通りの個別の測定値の算術手段であった。
本プロセスでは、繊維を一定の濡れ率で熱可塑性溶融に通過させる。ゆえに、繊維複合体プライの繊維体積含有率は、熱可塑性溶融の溶融体積流量における差異、および繊維複合体プライの生成率と生成対象となる繊維複合体プライの断面積との積から計算される。
上述の構成要素AおよびBから繊維複合体プライの生成する工程を、DE102011005462B3に記載されているプロセスに従って遂行した。スプレッドロービングから構成される乾燥繊維バンドを約220°Cの温度になるまで加熱した後、溶融ポリマーを、乾燥繊維バンドの平面の両側に塗布した。いったん圧力剪断振動の印加が遂行された後、繊維複合体プライからなる下記組成物が、エンドレステープとして得られた。
2:内側繊維複合体プライ
3:外側繊維複合体プライ
4:エンドレス繊維
5:ポリカーボネート系プラスチック
6:更に外側の材料プライ
7:更に内側の材料プライ
a:ラップトップモニター背面
b:ラップトップモニター
c:ラップトップキーボード
d:ラップトップ下面
Claims (12)
- 2つの外側繊維複合体プライ(3)および少なくとも4つの内側繊維複合体プライ(2)として相互に対して画定され、少なくとも6つの重畳した繊維複合体プライ(2,3)を備える多層複合体(1)であって、
(a)これら少なくとも6つの繊維複合体プライ(2,3)の各々が、エンドレス繊維(4)を備え、
− 前記それぞれのプライ(2,3)内の前記エンドレス繊維(4)が、単方向に整列配置され、且つ
− ポリカーボネート系プラスチック(5)の中に埋め込まれていて、前記ポリカーボネートが、ホモポリカーボネートまたはコポリカーボネートから選択され、
(b)内側繊維複合体プライ(2)が、同じ配向を有し、且つ外側繊維複合体プライ(3)を基準にした配向が30°〜90°回転し、前記繊維複合体プライ(2,3)の配向が、そのプライ内に存在する単方向に整列配置された繊維(4)の配向によって決まり、
(c)前記内側繊維複合体プライ(2)の繊維体積含有率が、前記繊維複合体プライの総体積を基準にして40〜60vol%であり、
(d)前記外側繊維複合体プライ(3)の繊維体積含有率が、前記繊維複合体プライの総体積を基準にして30〜50vol%であり、
(e)前記2つの外側繊維複合体プライ(3)の総和対全ての内側繊維複合体プライ(2)の総和の厚さ比率が、0.35〜0.65である、多層複合体(1)。 - 前記少なくとも6つの繊維複合体プライ(2,3)が、対称的に整列配置され、前記2つの外側繊維複合体プライ(3)が、化学組成、繊維体積含有率および層厚さを含む群からの少なくとも1つの特徴という観点で、同一の構築体を有する、請求項1に記載の多層複合体(1)。
- 前記多層複合体(1)の総厚さが、0.5mm〜2mmの範囲内にある、請求項1または2に記載の多層複合体(1)。
- 前記2つの外側繊維複合体プライ(3)の総和対全ての内側繊維複合体プライ(2)の総和の厚さ比率が、0.35〜0.58である、請求項1〜3のいずれか一項に記載の多層複合体(1)。
- 前記多層複合体(1)が、4〜6つの内側繊維複合体プライ(2)を備える、請求項1〜4のいずれか一項に記載の多層複合体(1)。
- 内側繊維複合体プライ(2)同士の配向が同じであり、且つ外側繊維複合体プライ(3)を基準にした配向が90°±5°回転する、請求項1〜5のいずれか一項に記載の多層複合体(1)。
- 前記少なくとも6つの繊維複合体プライ(2,3)の空隙率が、2vol%未満である、請求項1〜6のいずれか一項に記載の多層複合体(1)。
- 前記エンドレス繊維(4)が、ガラス繊維、カーボン繊維、玄武岩繊維、アラミド繊維、液晶ポリマー繊維、硫化ポリフェニレン繊維、ポリエーテルケトン繊維、ポリエーテルエーテルケトン繊維、ポリエーテルイミド繊維およびこれらの混合物からなる群から選択される、請求項1〜7のいずれか一項に記載の多層複合体(1)。
- 請求項1〜8のいずれか一項に記載の多層複合体(1)を生成するプロセスであって、
少なくとも4つの内側繊維複合体プライ(2)と、2つの外側繊維複合体プライ(3)とを提供する工程であって、前記個別の繊維複合体プライの生成が、溶融ポリカーボネート系プラスチックを乾燥繊維バンドに塗布することによって遂行され、前記プラスチックのガラス遷移温度を超えるまで予備加熱し、前記塗布工程が圧力剪断振動の印加下にて遂行され、前記ポリカーボネートが、ホモポリカーボネートまたはコポリカーボネートから選択される、前記提供工程と、
前記少なくとも4つの内側繊維複合体プライ(2)を前記外側繊維複合体プライ(3)間に導入する工程であって、内側繊維複合体プライ(2)同士の配向が同じであり、且つ外側繊維複合体プライ(3)を基準にした配向が、30°〜90°回転する、前記導入工程と、
前記層状の繊維複合体プライ(2,3)を結合し、前記多層複合体(1)を供給する工程と、を含む、多層複合体(1)の生成プロセス。 - 電子デバイスまたは電子デバイスの筐体として使用もしくは電子デバイスの筐体内に採用するための筐体パーツであって、請求項1〜8のいずれか一項に記載の多層複合体(1)を備える、電子デバイスまたは筐体パーツ。
- 前記電子デバイスが、モニター、タブレット、モバイル電話またはコンピュータである、請求項10に記載の電子デバイス。
- 前記電子デバイスの筐体が、ラップトップのモニター背面(a)または下面(d)である、請求項10に記載の筐体パーツ。
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