JPWO2012101793A1 - 繊維強化樹脂材とその製造方法 - Google Patents
繊維強化樹脂材とその製造方法 Download PDFInfo
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- JPWO2012101793A1 JPWO2012101793A1 JP2011532449A JP2011532449A JPWO2012101793A1 JP WO2012101793 A1 JPWO2012101793 A1 JP WO2012101793A1 JP 2011532449 A JP2011532449 A JP 2011532449A JP 2011532449 A JP2011532449 A JP 2011532449A JP WO2012101793 A1 JPWO2012101793 A1 JP WO2012101793A1
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- resin
- fiber reinforced
- reinforced resin
- adhesion layer
- base material
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Abstract
基材が連続繊維強化樹脂部材で少なくとも部分的に補強されてなる繊維強化樹脂材に関し、連続繊維強化樹脂部材を構成する連続繊維が蛇行することなく、しかも基材と連続繊維強化樹脂部材が良好に密着された繊維強化樹脂材とその製造方法を提供する。基材の少なくとも一部に連続繊維強化樹脂部材が補強材として積層されてなる繊維強化樹脂材であって、基材と補強材の間に双方を密着させる熱可塑性樹脂からなる密着層が介在し、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている。
Description
本発明は、基材である樹脂部材の少なくとも一部に、連続繊維がマトリックス樹脂である熱可塑性樹脂内に混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材とその製造方法に関するものである。
樹脂に強化用繊維材が混入されてなる繊維強化樹脂材(繊維強化プラスチック(FRP))は、軽量かつ高強度であることから、自動車産業や建設産業、航空産業など、様々な産業分野で使用されている。
たとえば自動車産業においては、ピラーやロッカー、床下フロアなどの車両の骨格構造部材や、ドアアウターパネルやフードなどの意匠性が要求される非構造部材に上記繊維強化樹脂材が適用され、車両の強度保証を図りながらその軽量化を実現し、低燃費で環境フレンドリーな車両を製造する試みがおこなわれている。
ところで、上記骨格構造部材や非構造部材を形成する基材は、平面状のもの、2以上の平面が交差した3次元形状もの、湾曲状もしくは湾曲面と平面が組み合わされた3次元形状のもの、さらにはこれらに補強用リブが一体に形成されたものなどがある。
上記基材は、たとえば50mm以下の長繊維材がマトリックス樹脂内に一方向に配向された素材から成形されているが、長繊維材を使用するために型内における成形性が悪いという課題を有している。
そして、この課題は、基材が上記リブ等の補強部材を一体に具備する場合に特に顕著であり、したがって、この成形性を改善するべく、基材(の少なくともリブ)をたとえば1mm以下の短繊維がマトリックス樹脂内にランダムに配向された樹脂材から成形する方法も適用されている。
このように短繊維から基材を成形した際には、基材の適所を連続繊維強化樹脂部材で補強することにより、基材の成形性を向上させながら、部分的に連続繊維強化樹脂部材で補強されて強度特性にも優れた繊維強化樹脂材を製造することができる。
ここで、連続繊維強化樹脂部材とは、50mmを超える繊維材がマトリックス樹脂内に一方向に配向された一方向材(UD材)や擬似等方材(多軸積層材や経糸および緯糸からなる織物など)からなるものである。
そして、このように基材とその一部が連続繊維強化樹脂部材から補強されてなる繊維強化樹脂材の製造方法は、成形型のキャビティに連続繊維強化樹脂部材を配し、次いでキャビティ内に基材用の溶融樹脂を射出したり、あるいは溶融樹脂を配してプレスすることにより、双方を密着させて一体化を図るものである(これらはいずれも、連続繊維強化樹脂部材の上に基材用の溶融樹脂をオーバーモールドすることから、オーバーモールディングと称される)。なお、プレヒートされた連続繊維強化樹脂部材を金型に配し、溶融したロングファイバ熱可塑性物質(LFT)を金型内に配してプレス成形することにより、部分的に連続繊維強化樹脂部材にて補強された繊維強化樹脂材を製造する方法が特許文献1に開示されている。
しかし、このオーバーモールディングにおいては、基材用の溶融樹脂の熱により、連続繊維強化樹脂部材がその融点以上に加熱されて軟化し、連続繊維強化樹脂部材を構成する連続繊維が蛇行してその物性を大きく低下させてしまうという課題があることが本発明者等によって特定されている。なお、たとえばこの連続繊維強化樹脂部材がUD材からなる場合に、連続繊維が蛇行してその角度が3度ずれるとその物性(引張強度)が10%程度、12度ずれると50%程度低下することが分かっている。
したがって、基材が連続繊維強化樹脂部材で部分的に、もしくは全体的に補強されてなる繊維強化樹脂材に関し、連続繊維強化樹脂部材を構成する連続繊維を蛇行させることなく、基材と連続繊維強化樹脂部材が良好に密着された繊維強化樹脂材とその製法開発が当該分野において急務の課題となっている。
本発明は上記する問題に鑑みてなされたものであり、基材が連続繊維強化樹脂部材で少なくとも部分的に補強されてなる繊維強化樹脂材に関し、連続繊維強化樹脂部材を構成する連続繊維が蛇行することなく、しかも基材と連続繊維強化樹脂部材が良好に密着された繊維強化樹脂材とその製造方法を提供することを目的とする。
前記目的を達成すべく、本発明による繊維強化樹脂材は、基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材であって、前記積層箇所において、基材と補強材の間に双方を密着させる熱可塑性樹脂からなる密着層が介在しており、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっているものである。
本発明の繊維強化樹脂材は、基材の適所に連続繊維強化樹脂部材からなる補強材が積層姿勢で密着することによって部分的に、もしくは全体的に補強された繊維強化樹脂材において、基材と連続繊維強化樹脂部材の積層箇所に双方を間接的に密着させる密着層が介在し、かつ、そのガラス転移点もしくは融点が連続繊維強化樹脂部材のマトリックス樹脂のガラス転移点もしくは融点よりも低いものであり、製造過程で密着層のみが先行して軟化もしくは溶融することにより、連続繊維強化樹脂部材を軟化もしくは溶融させることなく基材と連続繊維強化樹脂部材が良好に密着され、かつ連続繊維強化樹脂部材を構成する連続繊維の蛇行が抑制された繊維強化樹脂材である。
ここで、基材が非構造部材(意匠部材)の場合は、マトリックス樹脂のみからなる樹脂部材から形成された基材となり、骨格構造部材の場合は、短繊維や長繊維などがマトリックス樹脂内に混合された繊維強化樹脂部材から形成された基材となる。
さらに、基材と連続繊維強化樹脂部材、密着層それぞれのマトリックス樹脂は熱可塑性樹脂からなるが、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている。すなわち、少なくとも補強材と連続繊維強化樹脂部材は、双方が結晶性プラスチックからなる形態であっても非結晶性プラスチックからなる形態であっても、一方が結晶性プラスチックからなり、他方が非結晶性プラスチックからなる形態であってもよいが、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2の関係を満足するように双方のマトリックス樹脂が設定されている。
ここで、結晶性プラスチックとは、分子鎖が規則正しく配列された結晶領域の量の比率が高いもの、すなわち結晶化度の高いものを言い、ポリエチレン(PE)やポリプロピレン(PP)、ナイロン(PA:ナイロン6、ナイロン66など)、ポリアセタール(POM)、ポリエチレンテレフタレート(PET)などを挙げることができる。
一方、非結晶性プラスチックとは、結晶化度が極めて低いか、結晶化状態になり得ないものを言い、ポリスチレン(PS)、ポリ塩化ビニル(PVC)、ポリメタクリル酸メチル(PMMA)、ABS樹脂、熱可塑性エポキシなどを挙げることができる。
さらに、熱可塑性樹脂内に含有される繊維材としては、ボロンやアルミナ、炭化ケイ素、窒化ケイ素、ジルコニアなどのセラミック繊維や、ガラス繊維や炭素繊維といった無機繊維、銅や鋼、アルミニウム、ステンレス等の金属繊維、ポリアミドやポリエステルなどの有機繊維のいずれか一種もしくは2種以上の混合材を挙げることができる。
上記する繊維強化樹脂材によれば、密着層によって基材と連続繊維強化樹脂部材が良好に密着されるとともに、この密着の際に連続繊維強化樹脂部材のマトリックス樹脂が軟化や溶融されない、もしくは軟化や溶融され難いことから連続繊維の蛇行が抑制され、連続繊維強化樹脂部材の所期の物性(引張強度等)が保証された高強度な繊維強化樹脂材となる。
なお、上記する実施の形態の繊維強化樹脂材においては、基材の融点やガラス転移点と補強材および密着層の融点やガラス転移点との大小関係は特に規定されるものでない。
しかし、基材のマトリックス樹脂の融点やガラス転移点は少なくとも密着層の融点やガラス転移点よりも大きいものであり、好ましくは、補強材と基材それぞれのマトリックス樹脂が同素材のものから形成されているのがよい。密着層を介して一体化された繊維強化樹脂材において、双方の線膨張係数やヤング率等の物性が同一となり、設計管理が容易になるとともに双方が異なる熱変形量を呈することに起因する損傷を抑制できるからである。
また、本発明は繊維強化樹脂材の製造方法にも及ぶものであり、この製造方法は、基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材の製造方法であって、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層と補強材を用意するステップ、成形型のキャビティ内に補強材を配し、補強材の上に密着層を配し、基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなるものである。
本製造方法は、ともに定型の補強材と密着層(たとえば密着シート)を成形型内に配し、基材用の樹脂材料をキャビティ内にチャージして密着層のみを軟化もしくは溶融させて補強材と基材を適所で密着させるものである。ここで、「チャージ」とは、キャビティ内に溶融樹脂を射出することと、溶融樹脂の塊(プレヒートによる予備腑形体)をキャビティ内に配することの双方を含んでおり、後者の場合にはその後にプレス成形して基材と補強材の一体化が図られるものである。
この製造方法によれば、繊維強化樹脂材の製造過程において、基材用の樹脂材料をキャビティ内にチャージした際に密着層のみを軟化もしくは溶融させることにより、この密着層によって基材と連続繊維強化樹脂部材を良好に密着させることができ、しかも、この密着の際に連続繊維強化樹脂部材のマトリックス樹脂が軟化や溶融されない、もしくは軟化や溶融され難いことから連続繊維の蛇行が抑制され、連続繊維強化樹脂部材の所期の物性(引張強度等)が保証された高強度な繊維強化樹脂材を製造することができる。
また、本発明による繊維強化樹脂材の製造方法の他の実施の形態は、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層と補強材を用意し、双方を成形型内でプレスして中間体を製造するステップ、前記中間体を別途の成形型のキャビティ内に配し、基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなるものである。
さらに、本発明による繊維強化樹脂材の製造方法の他の実施の形態は、補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層用の樹脂材料と補強材を用意するステップ、成形型のキャビティ内に補強材を配し、密着層用の樹脂材料をキャビティ内にチャージして硬化させるステップ、基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなるものである。
上記いずれの形態の製造方法によっても、基材用の樹脂材料をキャビティ内にチャージした際に密着層のみを軟化もしくは溶融させることができる。
また、基材のマトリックス樹脂と連続繊維強化樹脂部材のマトリックス樹脂が同素材のものを適用することで、既述するように設計管理が容易になるとともに得られた繊維強化樹脂材が構成部材の異なる熱変形量等によって損傷するのを抑制することができる。
以上の説明から理解できるように、本発明の繊維強化樹脂材とその製造方法によれば、基材が連続繊維強化樹脂部材からなる補強材で部分的に補強されてなる繊維強化樹脂材において、補強箇所の基材と補強材の間に密着層が介在し、かつこの補強材のガラス転移点もしくは融点が密着層のガラス転移点もしくは融点よりも高いことにより、補強材を構成する連続繊維が蛇行することなく、しかも基材と補強材が良好に密着された繊維強化樹脂材を提供することができる。
以下、図面を参照して本発明の繊維強化樹脂材とその製造方法の実施の形態を説明する。なお、図示する繊維強化樹脂材は、リブを具備する基材の面材の全面を補強材で補強した構成であるが、基材はリブを具備しないものやその他多様な3次元形状のものであってもよく、さらには、補強材が基材の一部のみを補強するものであってもよいことは勿論のことである。
図1aは本発明の繊維強化樹脂材の一実施の形態の斜視図であり、図1bは図1aのb−b矢視図である。
図示する繊維強化樹脂材10は、平面状の面材1’とこの面材1’を補強するリブ1”が一体に成形されてなる基材1と、面材1’の全面に密着層3を介して密着して該面材1’を補強する補強材2とから大略構成されている。
基材1は、たとえばピラーやロッカー、床下フロアなどの車両の骨格構造部材であり、熱可塑性樹脂からなるマトリックス樹脂1a内に1mm以下の短繊維や50mm以下の長繊維といった不連続の繊維材1bのいずれか一方もしくは双方が混合されてなる樹脂材料から成形されている。より具体的には、面材1’を構成する繊維材1bが長繊維であり、リブ1”を構成する繊維材1bが短繊維からなる形態や、面材1'とリブ1”の双方を構成する繊維材1bがともに長繊維、もしくは短繊維からなる形態などがある。なお、基材がドアアウターパネルやフードなどの意匠性が要求される非構造部材の場合には、繊維材を具備しないマトリックス樹脂1aのみからなる樹脂材料から成形することができる。
一方、補強材2は、熱可塑性樹脂からなるマトリックス樹脂2a内に図1bで示すように一方向に配向された連続繊維2bが混合されてなる連続繊維強化樹脂部材となっている。
このように、図示する補強材2は50mmを超える連続繊維2bがマトリックス樹脂2a内に一方向に配向された一方向材(UD材)であるが、その他にも、擬似等方材(0度方向の方向材と90度方向の方向材、±45度方向の方向材、0度、90度、±45度方向の方向材などの複数の方向材が積層された多軸積層材や、経糸および緯糸からなる織物材など)を適用することもできる。
また、密着層3は熱可塑性樹脂からなるシート材、もしくは熱可塑性樹脂の溶融材料が成形型内でチャージされ、硬化したものなどからなる。
このように、基材1のマトリックス樹脂1a、補強材2のマトリックス樹脂2aおよび密着層3はいずれも熱可塑性樹脂からなるものであるが、これらはともに非結晶性プラスチックであってもよいし、結晶性プラスチックであってもよいし、いずれかが非結晶性プラスチックであり、他のものが結晶性プラスチックからなる形態であってもよい。
ここで、結晶性プラスチックとしてはたとえば、ポリエチレン(PE)やポリプロピレン(PP)、ナイロン(PA:ナイロン6、ナイロン66など)、ポリアセタール(POM)、ポリエチレンテレフタレート(PET)のいずれか一種を適用できる。
また、非結晶性プラスチックとしてはたとえば、ポリスチレン(PS)、ポリ塩化ビニル(PVC)、ポリメタクリル酸メチル(PMMA)、ABS樹脂、熱可塑性エポキシのうちのいずれか一種を適用できる。
さらに、熱可塑性樹脂内に含有される繊維材としては、ボロンやアルミナ、炭化ケイ素、窒化ケイ素、ジルコニアなどのセラミック繊維や、ガラス繊維や炭素繊維といった無機繊維、銅や鋼、アルミニウム、ステンレス等の金属繊維、ポリアミドやポリエステルなどの有機繊維のいずれか一種もしくは2種以上の混合材を適用できる。
ただし、補強材2のマトリックス樹脂2aが非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層3が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、以下のいずれかの関係式を満足するように双方のマトリックス樹脂が選定される。
Tg1>Tg2もしくはTm2 ・・・・・・・・・・・(1)
Tm1>Tg2もしくはTm2 ・・・・・・・・・・・(2)
また、好ましくは、上記関係式に加えて、基材1のマトリックス樹脂1aが補強材2のマトリックス樹脂と同素材のものから形成されているのがよい。密着層3を介して基材1と補強材2が一体化されてなる繊維強化樹脂材10において、基材1と補強材2の線膨張係数やヤング率等の物性が同一となり、設計管理が容易になるとともに双方が異なる熱変形量を呈することに起因する損傷を抑制できるからである。
Tm1>Tg2もしくはTm2 ・・・・・・・・・・・(2)
また、好ましくは、上記関係式に加えて、基材1のマトリックス樹脂1aが補強材2のマトリックス樹脂と同素材のものから形成されているのがよい。密着層3を介して基材1と補強材2が一体化されてなる繊維強化樹脂材10において、基材1と補強材2の線膨張係数やヤング率等の物性が同一となり、設計管理が容易になるとともに双方が異なる熱変形量を呈することに起因する損傷を抑制できるからである。
図示する繊維強化樹脂材10によれば、密着層3によって基材1と補強材2が良好に密着されるとともに、この密着の際に補強材2のマトリックス樹脂2aが軟化や溶融されない、もしくは軟化や溶融され難いことから連続繊維2bの蛇行が抑制され、補強材2の所期の物性(引張強度等)が保証された高強度な繊維強化樹脂材10となる。
次に、図2〜4を参照して、繊維強化樹脂材10の製造方法の実施の形態を概説する。
図2で示す製造方法の一実施の形態としては、まず、上記関係式(1)もしくは(2)を満たす補強材2と、たとえば定型シート材からなる密着層3を用意する(ステップS1)。
次に、不図示の成形型のキャビティ内に補強材2を配し、補強材2の上に密着層3を配し、補強材2と同素材の基材1用の樹脂材料、もしくは少なくとも密着層3のTmもしくはTgよりも高いTmもしくはTgを有する基材1用の樹脂材料をキャビティ内にチャージして密着層3のみを軟化もしくは溶融させ、該密着層3を介して補強材2と基材1が密着された繊維強化樹脂材10を製造する(ステップS2)。
ここで、ステップS2において基材1用の樹脂材料をチャージする形態としては大きく2つの方法がある。
その一つは、キャビティ内に溶融した基材1用の樹脂材料を射出する射出成形法である。
また、他の一つは、基材1用の樹脂材料をプレヒートして軟化もしくは溶融した予備腑形体を形成し、これをキャビティ内の補強材2の上に配してプレス成形する方法である。
この製造方法によれば、繊維強化樹脂材10の製造過程において、基材1用の樹脂材料をキャビティ内にチャージした際に密着層3のみを軟化もしくは溶融させることにより、この密着層3によって基材1と補強材2を良好に密着させることができ、さらには、この密着の際に補強材2のマトリックス樹脂が軟化や溶融されない、もしくは軟化や溶融され難いことから連続繊維2bの蛇行が抑制され、補強材2の所期の物性(引張強度等)が保証された高強度な繊維強化樹脂材10を製造することができる。
一方、図3で示す製造方法の実施の形態は、図2で示す製造方法と同様に、まず、上記関係式(1)もしくは(2)を満たす補強材2と、たとえば定型シート材からなる密着層3を用意する(ステップS1)。
次に、用意された補強材2を不図示の成形型のキャビティ内に配し、その上に定型シート材からなる密着層3をプレヒートして軟化もしくは溶融した予備腑形体を配してプレス成形することで中間体を製造する(ステップS2)。
次に、この中間体を不図示の別途の成形型のキャビティ内に配し、基材1用の樹脂材料をキャビティ内にチャージして密着層3を軟化もしくは溶融させ、該密着層3を介して補強材2と基材1が密着された繊維強化樹脂材10を製造するものである(ステップS3)。
さらに、図4で示す製造方法の実施の形態は、上記関係式(1)もしくは(2)を満たす補強材2と、密着層3用の樹脂材料を用意する(ステップS1)。
次に、不図示の成形型のキャビティ内に補強材2を配し、密着層3用の樹脂材料をキャビティ内にチャージしてこれを硬化させる(ステップS2)。
次に、この成形型のキャビティ内に基材1用の樹脂材料をキャビティ内にチャージして密着層3を軟化もしくは溶融させ、該密着層3を介して補強材2と基材1が密着された繊維強化樹脂材10を製造する(ステップS3)。
[補強材を構成する連続繊維の蛇行の有無を検証した実験とその結果]
本発明者等は、図1で示す形態の繊維強化樹脂材(実施例)と、この実施例から密着層を除いた従来構造の繊維強化樹脂材(比較例)をそれぞれ製作し、双方の補強材を構成する連続繊維の蛇行の有無を検証する実験をおこなった。
本発明者等は、図1で示す形態の繊維強化樹脂材(実施例)と、この実施例から密着層を除いた従来構造の繊維強化樹脂材(比較例)をそれぞれ製作し、双方の補強材を構成する連続繊維の蛇行の有無を検証する実験をおこなった。
この実験においては、実施例と比較例をそれぞれ材料を異ならせてそれぞれ2種類製作した。
実施例1は、基材をナイロンからなるマトリックス樹脂(ナイロン6のTmは約220℃、ナイロン66のTmは約260℃)内に不連続繊維が含有された樹脂材料から成形し、補強材を基材と同素材のナイロンからなるマトリックス樹脂内に連続繊維が含有された樹脂材料から成形し(UD材)、密着層を熱可塑性エポキシ(Tgは約105℃、120℃などのものがある)から成形し、不連続繊維および連続繊維としてガラス繊維や炭素繊維を使用し、図3で示す製造方法を適用して製造したものである。
これに対して、比較例1は、実施例1から密着層が省略されたものであり、成形型のキャビティ内に補強材を配し、溶融された基材用の樹脂材料をキャビティ内にチャージして比較例1の繊維強化樹脂材を製造した。
一方、実施例2は、基材をポリプロピレン(PP)からなるマトリックス樹脂(PPのTmは約160℃)内に不連続繊維が含有された樹脂材料から成形し、補強材を基材と同素材のポリプロピレン(PP)からなるマトリックス樹脂内に連続繊維が含有された樹脂材料から成形し、密着層を熱可塑性エポキシ(Tgは約105℃、120℃などのものがある)から成形し、不連続繊維および連続繊維としてガラス繊維や炭素繊維を使用し、同様に図3で示す製造方法を適用して実施例2の繊維強化樹脂材を製造した。
比較例1の繊維強化樹脂材を構成する補強材の横断面写真図を図5aに、その縦断面写真図を図5bにそれぞれ示しており、実施例1の繊維強化樹脂材を構成する補強材の横断面写真図を図5cに、その縦断面写真図を図5dにそれぞれ示しており、さらに、図5dを模擬した模式図を図5eに示している。
図5b、図5dを比較すると明らかであるが、比較例1の補強材を構成する連続繊維は大きく蛇行しているのに対して、実施例1の補強材を構成する連続繊維は蛇行することなく、ほぼ均一に一方向に配向していることが実証されている。
これは、補強材のTmよりも低いTgの密着層が基材と補強材の間に介在しているか否かに依拠するものであり、実施例1のように連続繊維の配向が一方向に均一に揃っていることで、補強材の所期の物性を保証することができ、もって高強度の繊維強化樹脂材となっている。
以上、本発明の実施の形態を図面を用いて詳述してきたが、具体的な構成はこの実施形態に限定されるものではなく、本発明の要旨を逸脱しない範囲における設計変更等があっても、それらは本発明に含まれるものである。
1…基材、1’…面材、1”…リブ、1a…マトリックス樹脂、1b…繊維材(長繊維材、短繊維材)、2…補強材(連続繊維強化樹脂部材)、2a…マトリックス樹脂、2b…連続繊維、3…密着層、10…繊維強化樹脂材
Claims (8)
- 基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材であって、
前記積層箇所において、基材と補強材の間に双方を密着させる熱可塑性樹脂からなる密着層が介在しており、
補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている繊維強化樹脂材。 - 基材のマトリックス樹脂と連続繊維強化樹脂部材のマトリックス樹脂が同素材である請求項1に記載の繊維強化樹脂材。
- 前記基材は繊維材がマトリックス樹脂内に混合されてなる繊維強化樹脂部材である請求項1または2に記載の繊維強化樹脂材。
- 基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材の製造方法であって、
補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層と補強材を用意するステップ、
成形型のキャビティ内に補強材を配し、補強材の上に密着層を配し、基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなる繊維強化樹脂材の製造方法。 - 基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材の製造方法であって、
補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層と補強材を用意し、双方を成形型内でプレスして中間体を製造するステップ、
前記中間体を別途の成形型のキャビティ内に配し、基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなる繊維強化樹脂材の製造方法。 - 基材である樹脂部材の少なくとも一部に、マトリックス樹脂である熱可塑性樹脂内に連続繊維が混合されてなる連続繊維強化樹脂部材が補強材として積層され、この積層箇所によって補強されてなる繊維強化樹脂材の製造方法であって、
補強材の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg1、結晶性プラスチックの場合はその融点をTm1、密着層の熱可塑性樹脂が非結晶性プラスチックの場合はそのガラス転移点をTg2、結晶性プラスチックの場合はその融点をTm2とした場合に、Tg1>Tg2もしくはTm2、もしくはTm1>Tg2もしくはTm2となっている密着層用の樹脂材料と補強材を用意するステップ、
成形型のキャビティ内に補強材を配し、密着層用の樹脂材料をキャビティ内にチャージして硬化させるステップ、
基材用の樹脂材料をキャビティ内にチャージして密着層を軟化もしくは溶融させ、該密着層を介して補強材と基材が密着された繊維強化樹脂材を製造するステップ、からなる繊維強化樹脂材の製造方法。 - 基材のマトリックス樹脂と連続繊維強化樹脂部材のマトリックス樹脂が同素材である請求項4〜6のいずれかに記載の繊維強化樹脂材の製造方法。
- 前記基材は繊維材がマトリックス樹脂内に混合されてなる繊維強化樹脂部材である請求項4〜7のいずれかに記載の繊維強化樹脂材の製造方法。
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DE102014106319A1 (de) * | 2014-05-06 | 2015-11-12 | Airbus Operations Gmbh | Verfahren und System zum Aufbringen einer Folie auf ein zur Aushärtung vorgesehenes Kunststoffwerkstück sowie Verfahren zur Herstellung eines Kunststoffwerkstücks |
EP3078475B1 (de) | 2015-04-07 | 2019-01-30 | Ems-Patent Ag | Herstellungsverfahren eines mit einem verstärkungselement verstärkten formkörpers |
JP6848409B2 (ja) * | 2015-12-25 | 2021-03-24 | 東レ株式会社 | 複合成形体 |
US9707898B1 (en) * | 2016-07-11 | 2017-07-18 | Ford Global Technologies, Llc | Extruded multi-layer molded running board |
US10183421B2 (en) | 2016-09-16 | 2019-01-22 | General Electric Company | Molding method |
US20180345604A1 (en) * | 2017-06-02 | 2018-12-06 | Arris Composites Llc | Aligned fiber reinforced molding |
CN109795513A (zh) * | 2017-11-17 | 2019-05-24 | 上海杰事杰新材料(集团)股份有限公司 | 一种铁路平车用复合地板及其制备方法 |
FR3087188B1 (fr) * | 2018-10-12 | 2021-05-21 | Airbus Operations Sas | Panneau structural raidi pour aeronef, presentant une conception amelioree |
US20200114596A1 (en) * | 2018-10-12 | 2020-04-16 | Arris Composites Inc. | Preform Charges And Fixtures Therefor |
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JPH02172731A (ja) * | 1988-12-26 | 1990-07-04 | Sekisui Chem Co Ltd | 長尺複合成形体 |
JPH02266935A (ja) * | 1989-04-07 | 1990-10-31 | Sekisui Chem Co Ltd | 長尺複合成形体及びその製造方法 |
JP3123761B2 (ja) * | 1991-02-18 | 2001-01-15 | 三井化学株式会社 | 表面改良された繊維補強樹脂成形品及びその成形方法 |
JPH1120017A (ja) | 1997-07-03 | 1999-01-26 | Keepura Sheet Kk | 繊維強化熱可塑性樹脂層を有する多層成形体とその成形方法 |
JP2000167863A (ja) * | 1998-12-09 | 2000-06-20 | Toyobo Co Ltd | ウェルド補強方法 |
CN100556674C (zh) | 2002-09-15 | 2009-11-04 | 地方小型汽车公司 | 由纤维增强热塑性材料制备结构件的方法、设备以及所制备的结构件 |
JP5153052B2 (ja) | 2004-05-12 | 2013-02-27 | 本田技研工業株式会社 | 繊維強化プラスチックおよび、その製造方法 |
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EP2669082A1 (en) | 2013-12-04 |
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EP2669082A4 (en) | 2014-09-03 |
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