JPS58205755A - Hybrid one-direction prepreg and its manufacture - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] The present invention relates to a novel prepreg and a method for manufacturing the same.

Various methods are used to mold fiber-reinforced composite materials, depending on the shape and purpose of the product. Currently, the most common methods in industrial production are the filament winding method and the lamination molding method using prepreg sheets. The prepreg sheet used in the lamination molding method is manufactured from a single fiber thread, which is integrally molded by heating, pressure, etc. Furthermore, the performance of prepregs is greatly influenced by the type of fibers used, and the quality of adhesion (wetting) between the reinforcing fibers and the matrix resin determines the physical properties of the product.

Carbon fiber is a fiber with excellent strength, but its disadvantages are that it is expensive and is brittle against impact. As a method to compensate for these shortcomings, a no-brid lamination method was developed, which is a method in which carbon fiber seed prepreg or woven fabric is sandwiched with other μ fiber prepreg, mat, or woven fabric. A carbon fiber laminate that is resistant to impact can be obtained. However, such laminates also have drawbacks, such as delamination problems due to tension or stress, and poor flow of resin between each sheet, which tends to affect later interlaminar shear strength. Separately preparing various prepregs, fabrics, etc. for lamination and layering them in an orderly manner is a time-consuming task and extremely inefficient.

The present inventor completed the present invention as a result of research into a method for eliminating these drawbacks and simplifying the labor of hybrid lamination.

In the present invention, a carbon fiber yarn of a predetermined thickness and one or more types of other type of fiber yarn are arranged adjacent to each other in the width direction, and a matrix resin is impregnated between the fibers, and the other type of fiber yarn is arranged in a predetermined manner. After arranging the fibers in the same arrangement, the yarns are widened until they come into contact with each other to form a sheet-like product, and then the sheet-like product is impregnated with a matrix resin.

As the matrix resin, thermosetting resins such as epoxy resins, phenolic resins, polyester resins, and polyimide resins, thermoplastic resins such as nylon 66, polycarbonate resins, polybutadiene terephthalate-1 resin, and ABS resins are used.

Fibers other than carbon fiber include aromatic polyamide fiber,
Glass fiber, alumina fiber, silicon carbide fiber,
Examples include titanium fiber and boron fiber.

When producing the prepreg of the present invention, carbon fiber threads and one or more types of other fiber threads are aligned in a predetermined arrangement, and then each thread is widened until they are adjacent to each other to form a sheet-like product. .

As a method of widening the yarn, for example, by applying tension in the longitudinal direction and forming an edge in advance.
Methods such as rubbing the yarn, spreading the yarn one by one through a large number of tension rollers, pressing with a roller, and using a fluid are used.

Matrix 3- When impregnated with resin, the prepreg of the present invention is obtained.

Any type of fiber thread may be used as long as it has a low pink shape, but it is necessary that the fiber threads to be widened be in the form of a mass each having a certain area. In addition, it is relatively easy to expand the width of untwisted yarns, but it is difficult to expand the width of twisted yarns, resulting in a narrow width.

By using the prepreg of the present invention, it is possible to simplify the labor of laminating layers when molding a fiber-reinforced composite material. Moreover, a laminated product with added fashion properties can be obtained.

An example of the structure of the prepreg of the present invention will be explained with reference to the drawings.

FIG. 1 is an enlarged schematic diagram showing a longitudinal section of a hybrid unidirectional prepreg made of untwisted fiber yarns; ) are arranged in a certain order and then impregnated with matrix resin (3) to form a sheet-like product. FIG. 1 CB) is a schematic diagram showing a structure in which the sheet-like materials of [A] are hybrid-laminated with their positions slightly shifted during 4-layer lamination. FIG. 2 is an enlarged schematic diagram showing a longitudinal section of a hybrid unidirectional prepreg of untwisted carbon fiber yarn and twisted other fiber yarn;
) and twisted other types of fibers (4) are arranged in a certain order to form a warp-knitted shape, and then impregnated with matrix resin (6) to form a sheet-like product.

Example 1 Untwisted acrylic carbon fiber #F-(diameter 8μ x number of filaments 6000) -(a) 3 fibers and untwisted Kevl
ar (trademark of Shuhan Co., Ltd.) (diameter 7 μ x number of filaments 600) - (b) 1' Using 0 filaments, (a) 1
After arranging (b) 5 yarns in a book from the right end to the left end, the prepared edges are rubbed, the width is widened until the yarns come into contact with each other, a warp-knitted sheet is formed, and a hardening agent is applied. The product is impregnated with the epoxy resin contained in it, sandwiched between release paper, dried and desolventized, and then rolled up with a winder while being pressed with a roller, resulting in a width of 600 lines and a thickness of 0° as shown in Figure 1 [A]. A 25-degree hybrid unidirectional prepreg is obtained. This was cut into 20 sheets with a length of 220 mm and a width of 100 mm, stacked in the 0° direction as shown in Figure 1 [B], and pressed at a pressure of 6
After curing for 1 hour at 7 kg/cm2 and 170 DEG C., a 4.5 mm thick plate with a black and yellow knitted pattern is obtained. The performance of this board is 100% carbon fiber and Ke
It was almost equivalent to hybrid lamination of alternating 100% vlar prepregs.It was also easy to use,
In particular, no delamination was observed.

Example 2 Untwisted carbon fiber i-axis i-mi (diameter 8μ x number of filaments 1o
(c) Kevlar with 6 twists and 20 twists per meter (diameter 7 μ x number of filaments 600) - (d) 15 twists from the right end to the left (C) for one (d) Arrange the threads at a ratio of 6, rub the edges, widen the threads until they come into contact with each other to form a sheet, impregnate it with a polycarbonate resin containing a curing agent, and sandwich it between release paper; After drying, it is pressed with a roller and wound up with a winding machine to obtain a hybrid unidirectional prepreg with a width of 600 mm and a thickness of 0.2 mm as shown in Fig. 2. This was cut into 20 sheets with a length of 220 mvt and a width of 100 mm, simply laminated in the 0° direction, and cured for 10 minutes at a press pressure of 70 kg/cm'' and a temperature of 260°C, resulting in a thickness of 3.5 mm. A fashionable laminate with yellow lines on a black background is obtained.

7 Example 6 Untwisted acrylic carbon fiber yarn (diameter 8μ x number of filaments 10,000) 7-(e) 6 and untwisted glass fiber (diameter 7μ x number of filaments 200) -(f
) Use 15 yarns, arrange them from the right end to the left end in a ratio of (e) to 1 (f) 3 yarns, and pass through the 5 provided tension rollers until the yarns touch each other. It is widened to form a sheet, impregnated with epoxy resin containing a curing agent, sandwiched with release paper, dried, and then rolled up by pressing with a roller to form a sheet with a width of 20 mm as shown in Figure 1 [A].
A hybrid unidirectional prepreg with a thickness of 0 mm and a thickness of 0.18 mm is obtained. This was cut into 10 pieces 300 mm long and 200 mm wide, spray coated with a mold release agent, wrapped around a 2.5 cm diameter -v groove in the 0° direction, and wrapped with pressure tape on the outermost side. After wrapping and curing in an autoclave at 170°C for 1 hour, a very fashionable black and silver warp-knitted pipe with a diameter of 2.5 crn is obtained.

8-

[Brief explanation of drawings]

Figure 1 [A] is a hybrid unidirectional prepreg made of untwisted fiber yarns, [B] is an enlarged schematic diagram showing one mode of laminating this prepreg, and Figure 2 is an untwisted carbon fiber yarn. This is an enlarged schematic diagram of a hybrid unidirectional prepreg of twisted and twisted other fiber yarns, in which symbol (1) is untwisted carbon fiber, (2) is untwisted other fiber, and (6) is untwisted other fiber yarn. Matrix resin, (4) ” indicates twisted other types of fiber. Applicant: Mitsubishi Rayon Co., Ltd.

Claims (1)

[Claims] 1. A hybrid unidirectional carbon fiber yarn of a predetermined thickness and one or more types of other fiber yarns are arranged adjacent to each other in the width direction, and a matrix resin is impregnated between the fibers. prepreg. 2. After arranging the carbon fiber yarn and one or more other types of fiber yarn in a predetermined arrangement, each yarn is widened until it touches each other to form a sheet-like object, and then a matrix is applied to the sheet-like object. A method for producing a hybrid unidirectional prepreg, characterized by impregnating it with a resin.