JPH03199009A - Hybrid prepreg and production thereof - Google Patents

Abstract

PURPOSE:To enhance physical properties such as mechanical strength and to make the touch pleasant at the time of utilization by arranging dissimilar fiber having specified fiber diameter into the reinforced fiber having specified fiber diameter at the prescribed interval to the same direction as the reinforced fiber. CONSTITUTION:Carbon fiber having fiber diameter of 5-30mum is utilized as reinforced fiber 2. Dissimilar fiber 6 having fiber diameter of 50-500mum is arranged to the same direction as the arrangement direction of the carbon fiber on a first carbon fiber reinforced prepreg 4A held on release paper 10. Furthermore, a second carbon fiber reinforced prepreg 4B held on the release paper 10 is superposed in a state wherein it pinches the dissimilar fiber 6. The first carbon fiber reinforced prepreg 4A, the dissimilar fiber 6 and the second carbon fiber reinforced prepreg 4B are integrally joined by pressing and/or heating both carbon fiber reinforced prepregs 4A, 4B and thereby a hybrid prepreg 1 is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION 1. The present invention provides reinforcing fibers such as carbon fibers with small fiber diameters and reinforcing fibers with large fiber diameters (including the "converted diameter" described later), which are different from the reinforcing fibers. Hybrid prepregs having reinforcing fibers such as metal fibers such as titanium fibers, amorphous fibers, and stainless steel fibers; inorganic fibers such as boron fibers and glass fibers; or different types of fibers such as various organic fibers; This relates to a manufacturing method.

In recent years, prepregs using carbon fiber and various other reinforcing fibers have been widely used in various technical fields.
It is often used in the manufacture of golf shafts and fishing rods because it is lightweight and has high mechanical strength.
It has achieved very good results.

However, further improvements are desired in terms of strength and modulus of elasticity, or in terms of feel during use. For example, methods of using different types of fibers such as boron fibers, titanium fibers, amorphous fibers, stainless steel fibers, glass fibers, and various organic fibers as reinforcing fibers have been proposed, and research on this purpose is being actively conducted.

At present, as a hybrid prepreg for this purpose, one having a configuration as shown in FIG. 8 has been proposed and is in use.

In other words, the hybrid prepreg shown in FIG. 8 is formed by arranging different types of fibers 6 different from the reinforcing fibers 2 at equal intervals on a prepreg 4 using reinforcing fibers 2 such as carbon fibers. .

Although such a hybrid prepreg can be easily manufactured and can achieve improved mechanical strength and improved feel, the bonding between the prepreg 4 and the different fibers 6 is insufficient, and the desired mechanical strength cannot be achieved sufficiently. This is a problem because there are things that cannot be performed to the fullest. Also, boron fiber, titanium fiber, amorphous fiber,
The diameter of the different types of fibers 6 such as stainless steel fibers is large, and therefore, the thickness of the hybrid prepreg must also be generally large, and there is also the problem that it is difficult to provide a thin hybrid prepreg. was.

Therefore, an object of the present invention is to provide reinforcing fibers with a small fiber diameter, which can improve physical properties such as mechanical strength compared to conventional hybrid prepregs, and can provide thin prepregs. It is an object of the present invention to provide a hybrid prepreg using different types of fibers having a large fiber diameter and a method for manufacturing the same.

Furthermore, as will be explained in detail later, another object of the present invention is to arrange reinforcing fibers and different types of fibers without disturbance in the length direction of the fibers, so that the prepreg has good mechanical properties and is aesthetically pleasing. Another object of the present invention is to provide a method for producing a hybrid prepreg that is also preferable.

The above-mentioned methods for achieving the following can be achieved by the hybrid prepreg and method for producing the same according to the present invention. In summary, the present invention provides reinforcing fibers having a fiber diameter of 5 to 30 tLm, in which different types of fibers having a fiber diameter of 50 to 500 tLm are arranged at predetermined intervals in the same direction as the reinforcing fibers. This is a hybrid prepreg with special characteristics.

Such a hybrid prepreg according to the present invention is made of two unidirectional fiber-reinforced prepregs using reinforcing fibers with a fiber diameter of 5 to 30 μm, which are arranged at a predetermined interval in the same direction as the reinforcing fibers. Fiber diameter is 50-500
It is suitably manufactured by a manufacturing method characterized by sandwiching and integrating different fibers having a diameter of .mu.m, and can be efficiently realized in particular by using a drum winder. In other words, in the hybrid prepreg according to the present invention, (a) a unidirectional fiber-reinforced prepreg using reinforcing fibers with a fiber diameter of 5 to 30 μm is placed on the circumferential surface of a drum having a predetermined diameter in an arrangement of reinforcing fibers. a step of winding the unidirectional fiber-reinforced prepreg so that its direction is aligned in the circumferential direction of the drum; (b) on the circumferential surface of the unidirectional fiber-reinforced prepreg wrapped around the drum, fibers having a diameter of 50 to 5001 Lm different from the reinforcing fibers of the prepreg are formed; a step of winding the different types of fibers at a constant pitch; (C) in the state of being wound around the drum or in the state of being removed from the drum, the surface of the unidirectional fiber-reinforced prepreg on which the different types of fibers are arranged; covering the drum with another unidirectional fiber-reinforced prepreg using reinforcing fibers having a fiber diameter of 5 to 30 μm so that the reinforcing fibers are aligned in the circumferential direction of the drum. It is suitably manufactured by a manufacturing method characterized by the following.

Next, the hybrid prepreg and method for manufacturing the same according to the present invention will be explained in more detail with reference to the drawings.

FIG. 1 shows an embodiment of a hybrid prepreg l according to the present invention. According to this example, the fiber diameter is 5 to 3
It is constructed by arranging different types of fibers 6 having a fiber diameter of 50 to 500 μm at predetermined intervals in the same direction as the carbon fibers in a prepreg 4 having carbon fibers as reinforcing fibers 2 having a diameter of 0 μm. . At this time, the different types of fibers 6 are preferably located at the center of the unidirectional carbon fiber prepreg 4 as shown in FIG. However, the same effects can be achieved.

The hybrid prepreg 1 having such a structure can be manufactured by various methods, but in particular, between two unidirectional carbon fiber reinforced prepregs using carbon fibers as reinforcing fibers, a different type of fiber is mixed with the same carbon fiber. It is very suitably manufactured by arranging the parts at predetermined intervals in the direction and integrating them by pressing and/or heating.

To explain further, as shown in FIG.
The fiber diameter is 5 to 30 μm as the reinforcing fiber 2 held in
On the first carbon fiber-reinforced prepreg 4A having carbon fibers, the fibers are arranged in the same direction as the arrangement direction of the carbon fibers 2 of the first carbon fiber-reinforced prepreg 4A, and the fiber diameter is the same as that of the carbon fibers. Different types of fibers 6 having a relatively large fiber diameter of 50 to 500 ILm were arranged, and the different types of fibers 6 were further held in a release paper 10 similar to the first carbon fiber reinforced prepreg 4A in a manner to sandwich the different types of fibers 6. The second carbon fiber-reinforced prepreg 4B is superimposed, and the bidimensional fiber-reinforced prepreg 4
By pressing and/or heating A and 4B toward each other, the first carbon fiber reinforced prepreg 4A, the dissimilar fibers 6, and the second carbon fiber reinforced prepreg 4B are joined together, as shown in FIG. 1 or 2. A hybrid prepreg l according to the invention as illustrated in FIG.

The carbon fibers serving as the reinforcing fibers 2 of the first and second carbon fiber reinforced prepregs 4A and 4B may be the same carbon fiber, or may be carbon fibers with different strengths.

Furthermore, different types of reinforcing fibers may be used for the prepreg 4A and the prepreg 4B.

In this way, the reinforcing fibers 2 are not limited to carbon fibers, and may also include inorganic fibers such as boron fibers with small fiber diameters, glass fibers, alumina fibers, silicon carbide fibers, and silicon nitride fibers; aramid fibers, Organic fibers such as polyarylate fibers and polyethylene fibers; or metal fibers such as titanium fibers, amorphous fibers, and stainless steel fibers having small fiber diameters can be arbitrarily used.

The reinforcing fiber 2 has a fiber diameter of 5 to 30 μm, preferably 6 to 12 μm.

As the different fibers 6, inorganic fibers such as boron fibers, which have a larger fiber diameter than the reinforcing fibers 2, and metal fibers such as titanium fibers, amorphous fibers, and stainless steel fibers are preferably used. is 50-150μ
m, preferably 70 to 120 μm.

Furthermore, according to the present invention, glass fiber,
Inorganic fibers such as alumina fibers, silicon carbide fibers, and silicon nitride fibers; organic fibers such as aramid fibers, polyarylate fibers, and polyethylene fibers can also be used. However, these fibers generally have a small fiber diameter, that is, a monofilament diameter (d) of 5 to 50 μm. It is used in the form of a strand (fiber bundle) 6, which is made by bundling a large number of fibers 6a together.

Therefore, it is also possible to use metal fibers with small fiber diameters in the form of strands.

Different types of fibers 6 in the form of such strands
In this specification, the fiber diameter is defined as the converted diameter D0 expressed by the following formula.

D, = r lower d n: Number of convergent strands d: Fiber diameter Also, when such strands are used as the dissimilar fibers 6, regardless of the presence or absence of twisting, as shown in Fig. 5,
In the hybrid prepreg l, it does not exist in the form of a circular cross section with a reduced diameter D0, but is usually deformed into a flattened state. Therefore, as mentioned above, it is necessary to manufacture a hybrid prepreg l having the same thickness (T) as when using boron fibers, titanium fibers, amorphous fibers, stainless steel fibers, etc. with large fiber diameters as the different fibers 6. The strands are made of different fibers6
When used as a fiber, the fiber diameter, ie, the converted diameter D0, is preferably 500 μm at maximum.

For example, when 300 organic fibers such as polyarylate fibers have a fiber diameter d of 23 μm, the converted diameter D0 is 398 μm, and the fiber diameter d is 13 μm.
By converging 800 glass fibers, the converted diameter Do is 368 μm, and both of these strands are also suitably used as the different fibers 6 to produce a hybrid prepreg 1 as shown in FIG. can do.

As the matrix resin, thermosetting matrix resins such as epoxy resin, unsaturated polyester resin, polyurethane resin, diallyl phthalate resin, and phenol resin can be used. Furthermore, a curing agent and other imparting agents, such as a flexibility imparting agent, should be appropriately added so that the curing temperature is 50 to 500°C.

To give a preferable example, the matrix resin is preferably an epoxy resin, and examples of usable epoxy resins include (1) glycidyl thiethyl epoxy resin (
Bisphenol A, F, S-based epoxy resin, novolac-based epoxy resin, brominated bisphenol A-based epoxy resin) (2) Cycloaliphatic epoxy resin; (3) Glycidyl ester-based epoxy resin; (4) Glycidylamine-based epoxy resin (5) Heterocyclic epoxy resin: One or more types selected from various other epoxy resins are used, and bisphenol A, F, and S glycidylamine-based epoxy resins are particularly preferably used. Further, as the curing agent, diaminophenyl sulfone (DDS), diaminodiphenylmethane (DDM), etc. are preferably used.

Further, the blending ratio of reinforcing fibers, different types of fibers, and matrix resin in the hybrid of the present invention can be adjusted arbitrarily, but generally, in weight%, reinforcing fibers: different types of fibers: matrix resin = (40 to 80): (2 to 80) 20): (20~6
0). Further, according to the present invention, the thickness (T) of the prepreg can be made to be approximately the same as the fiber diameter of the different types of fibers used, but will usually be about 80 to 200 um.

Furthermore, the hybrid prepreg according to the present invention
It can also be manufactured by the method illustrated in the figure.

That is, the reinforcing fibers 2 and different types of fibers 6 are arranged at predetermined intervals on the first coated paper 14A coated with the matrix resin 12, and then the reinforcing fibers 2 and different types of fibers 6 are covered to form a matrix. Second coated paper 14B coated with resin 12
A hybrid prepreg 1 according to the present invention as shown in FIG. 1 is manufactured by overlapping the coated papers and then heating and pressurizing both coated papers.

Next, the hybrid prepreg and method for manufacturing the same according to the present invention will be explained in more detail. In this example, a preferred manufacturing method using drum wine goo will be described.

In FIG. 7, unidirectional carbon fiber reinforcement using, for example, carbon fiber as reinforcing fibers is held on a release paper IO as shown in FIG. Wrap prepreg 4A. At this time, the arrangement direction of the carbon fibers 2 is arranged in the circumferential direction of the drum 20. Next, the drum 20 has a bobbin 24
The different types of fibers 6 are supplied from the traverse device 26 and wound at a constant pitch onto the drum 20, that is, onto the carbon fiber reinforced prepreg 4A wound around the drum.

Next, the surface of the unidirectional carbon fiber reinforced prepreg 4A in which the different types of fibers 6 are aligned is covered, and as shown in FIG. are stacked on the surface of the drum 20 so that the fiber directions are aligned in the circumferential direction, and are bonded to the first carbon fiber reinforced prepreg with different types of fibers sandwiched therebetween,
When combined, a hybrid prepreg is formed having a cross-sectional configuration according to the invention as shown in FIG.

Note that as an alternative method, the second carbon fiber reinforced prepreg 4
In B, the first carbon fiber-reinforced prepreg 4A with different types of fibers 6 arranged on top of the first carbon fiber reinforced prepreg 4A can be layered after being removed from the drum, and if necessary, passed between hot rollers or the like.

First and second carbon fiber reinforced prepregs 4A, 4 used
B has the same configuration, with a thickness of 65 μm on release paper.
The carbon fibers used as the reinforcing fibers 2 were PAN-based carbon fibers (manufactured by Toshi Co., Ltd., trade name: rM40J) with a fiber diameter of 6.5 μm, and matrix resin used epoxy resin. Further, the content of matrix resin was 35% by weight.

As the different types of fibers 6, boron fibers and titanium fibers were used.

The boron fibers used had a fiber diameter of 1100 u and were arranged at intervals of 1 mm. In addition, titanium fiber has a fiber diameter of 11
00u were used, arranged at 2 mm intervals.

The hybrid prepreg l produced in this way is 1
A piece with a width of 300 mm and a length of 1.7 m was obtained. The thickness (T) of the hybrid prepreg using boron fiber as the different fiber 6 is 138 μm, the matrix resin content is 31.5% by weight, and the thickness (T) of the hybrid prepreg using titanium fiber as the different fiber 6. is 134
μm, and the matrix resin content was 3230% by weight.

In addition, the mechanical strength and other properties of such hybrid prepreg were measured, and the hybrid prepreg according to the present invention was superior to the conventional hybrid prepreg shown in FIG. 8 in both compressive strength and elastic modulus despite its thinner thickness. It also had a good feel during use.

Furthermore, compared to the manufacturing method shown in FIG. 6, the manufacturing method of the hybrid prepreg of the present invention using the drum winder eliminates the need to alternately arrange carbon fibers and different types of fibers on the coated paper. The prepreg had good properties, no disturbance in the longitudinal direction of the fibers, improved mechanical properties of the prepreg, and was aesthetically pleasing.

Since the hybrid prepreg according to the present invention is configured as described above, it can improve physical properties such as mechanical strength compared to conventional hybrid prepregs, and is easy to use. It has the characteristics of being able to provide a thin prepreg with a good feel when applied, and furthermore,
According to the manufacturing method of the present invention, reinforcing fibers such as carbon fibers and different types of fibers are arranged without disturbance in the longitudinal direction of the fibers, resulting in a hybrid prepreg that has good mechanical properties and is aesthetically pleasing. It has the advantage of being able to provide

[Brief explanation of drawings]

1 and 2 are cross-sectional configuration diagrams of a hybrid prepreg according to the present invention. FIG. 3 is a cross-sectional view illustrating one method of manufacturing a hybrid prepreg according to the present invention. FIG. 4 is a cross-sectional view of a strand showing one form of dissimilar fibers used in the present invention. FIG. 5 is a cross-sectional configuration diagram of another embodiment of the hybrid prepreg according to the present invention. FIG. 6 is a sectional view illustrating another method of manufacturing a hybrid prepreg according to the present invention. FIG. 7 is a perspective view illustrating a preferred method of manufacturing a hybrid prepreg according to the present invention. FIG. 8 is a cross-sectional configuration diagram of a conventional hybrid prepreg. 4. 1: Hybrid prepreg 2: Reinforced fibers 4A, 4B: Fiber reinforced prepreg 6: Different types of fibers 20 Ni drums Fig. 5 Fig. 3

Claims (1)

[Scope of Claims] 1) Among the reinforcing fibers having a fiber diameter of 5 to 30 μm, different types of fibers having a fiber diameter of 50 to 500 μm are arranged in the same direction as the reinforcing fibers at a predetermined interval. A hybrid prepreg characterized by 2) Two unidirectional fiber-reinforced prepregs using reinforcing fibers with a fiber diameter of 5 to 30 μm are arranged in the same direction as the reinforcing fibers and at a predetermined interval.
A method for producing a hybrid prepreg, which comprises sandwiching and integrating different types of fibers having a diameter of 0 to 500 μm. 3) (a) A unidirectional fiber-reinforced prepreg using reinforcing fibers with a fiber diameter of 5 to 30 μm is placed on the circumferential surface of a drum having a predetermined diameter, with the reinforcing fibers aligned in the circumferential direction of the drum. (b) On the circumferential surface of the unidirectional fiber-reinforced prepreg wound around the drum, dissimilar fibers having a fiber diameter of 50 to 500 μm, which is different from the reinforcing fibers of the prepreg, are arranged at a constant pitch. (c) In the state of being wound around the drum or in the state of being removed from the drum, the surface of the unidirectional fiber-reinforced prepreg in which the different types of fibers are aligned is further covered so that the fiber diameter is 5.
Production of a hybrid prepreg comprising the step of overlapping another unidirectional fiber-reinforced prepreg using reinforcing fibers with a diameter of ~30 μm so that the reinforcing fibers are aligned in the circumferential direction of the drum. Method.