JPWO2016043156A1 - 切込プリプレグおよび切込プリプレグシート - Google Patents
切込プリプレグおよび切込プリプレグシート Download PDFInfo
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- JPWO2016043156A1 JPWO2016043156A1 JP2015551081A JP2015551081A JPWO2016043156A1 JP WO2016043156 A1 JPWO2016043156 A1 JP WO2016043156A1 JP 2015551081 A JP2015551081 A JP 2015551081A JP 2015551081 A JP2015551081 A JP 2015551081A JP WO2016043156 A1 JPWO2016043156 A1 JP WO2016043156A1
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- cutting
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Links
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Images
Classifications
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- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
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- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
- B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
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Abstract
Description
(曲面成形)
曲率半径10mmの曲面を有する雌型とバグフィルムにより密閉空間を形成し、当該密閉空間に切込プリプレグを16〜32層積層した積層体を配置し、密閉空間を真空引きして大気圧との差圧で切込プリプレグ積層体を加圧しながら、加熱して固化させ繊維強化プラスチックを得る。
テープ状支持体Bとしてポリエチレンフィルムを貼り付けた切込プリプレグシートを100mm×100mmのサイズに切り取り、一つの角を含む10mm×10mmの領域にセロハンテープを貼り、セロハンテープ対角に向かってめくることでポリエチレンフィルムを剥がし、ポリエチレンフィルムの剥がしやすさを評価した。表1では、全てのポリエチレンフィルムを剥がすために要する手間を以下の3段階にわけた。
ポリエチレンフィルムを一度に剥がすことができたもの。
1〜3回10mm×10mmのセロハンテープを貼りなおして
ポリエチレンフィルムを剥がす必要があったもの。
4回以上10mm×10mmのセロハンテープを貼りなおして
ポリエチレンフィルムを剥がす必要があったもの。
サイズが100mm×100mmで、積層構成が[45/0/−45/90]2sの切込プリプレグの積層体を予めプレス機の内部で130°に加熱された金属板に挟み、3MPaの面圧をかけてプレス成形した。成形時間は、切込プリプレグが十分硬化させるため90分とし、加圧開始から90分後に取り出した。プレス成形により伸張した成形品の面積をプレス成形前の切込プリプレグの積層体の面積で割り、伸張率を計算した。
切込プリプレグから300mm×300mm、積層構成が[+45/0/−45/90]2sの切込プリプレグの積層体を作製し、350mm×350mmの型を用いてプレス機により3MPaの面圧の下でプレス成形し、350mm×350mmの繊維強化プラスチックを成形した。プレス時の温度は130度、プレス後に90分保持してから脱型し、室温に放置して冷却した。成形された繊維強化プラスチックの表面品位を目視により確認した。表1では、切込の存在がほとんど認識できないものをA、切込の開口は少ないものの切込の存在が認識されるものをB、切込が開口し表面品位が損なわれている場合にCと評価した。
切込プリプレグから300mm×300mm、積層構成が[+45/0/−45/90]2sの切込プリプレグの積層体を作製し、350mm×350mmの型を用いてプレス機により3MPaの面圧の下でプレス成形し、350mm×350mmの繊維強化プラスチックを成形した。プレス時の温度は130度、プレス後に90分保持してから脱型し、室温に放置して冷却した。強化繊維の0度方向が長手方向となるように、25mm×250mmの試験片を切り出し、ASTM D3039(2008)に規定された方法で引張試験を行った。測定した試験片の数は各水準5本とし、引張弾性率および引張強度の平均値を代表値として算出する。
13質量部のPES5003Pを、混練機中の60質量部の“アラルダイト(登録商標)”Y9655および40質量部の“エポン(登録商標)”825に加えて溶解させ、熱可塑性樹脂粒子である微粒子を20質量部混練し、次いで硬化剤として“アラドゥール(登録商標)”9664−1を45質量部混練して熱硬化性樹脂組成物を作製した。
実施例1の一方向プリプレグシートを用い、切込を挿入しない以外は、実施例1と同様にL字部材を成形し、R部のボイド率を計測した。層内に小さなボイドが点在し、ボイド率は1.5%であった。また、プリプレグ積層体の厚み中心より片面型側にシワが発生した。
実施例1の一方向プリプレグシート作製工程において、熱硬化性樹脂組成物の含浸をローラー温度140℃、ローラー圧力0.14MPaで実施した。含浸率を実施例1の方法で計測したところ、100%であった。その後、実施例1と同様に切込を挿入し、L字部材を成形し、R部のボイド率を計測した。層間に残留するボイドが多数みられ、ボイド率は2.0%であった。また、シワの発生は見られなかった。
比較例2と同様の含浸率100%の一方向プリプレグを用い、切込を挿入することなく、実施例1と同様にL字部材を成形し、R部のボイド率を計測した。繊維のブリッジングが目立ち、その直下に大きなボイドが生成されており、ボイド率は8.1%であった。また、プリプレグ積層体の厚み中心より片面型側にシワが発生した。
トレカ”(登録商標)プリプレグシートP3252S−15(強化繊維:T700S、樹脂:2592、強化繊維の体積含有率:56%、片面ポリエチレンフィルム、もう片面離型紙を積層)を、シリンダーに刃を配置したローラーカッターに繊維方向に挿入し、切込プリプレグシートを作製した。図2に示すように、強化繊維を垂直に横切る方向へ断続的な切込が設けられており、切込を強化繊維の垂直方向に投影した投影長さWsは、切込の長さYと等しく1mmであり、強化繊維の長手方向に断続的な切込同士に囲まれる領域において実質的に強化繊維のすべてが繊維長さLが24mmの強化繊維に分断されているカットパターンとした。プリプレグシートの表面にはポリエチレンフィルムが密着しており、ローラーカッターにプリプレグを繊維方向に挿入し切込を入れる際に、ポリエチレンフィルムを貫通してプリプレグに切込を挿入し、刃の先端が離型紙の内部に留まるようにした。切込挿入後の離型紙を切込を横切るように裁断し、その断面を光学顕微鏡で観察したところ、離型紙の厚み方向に40%まで切込が侵入していた。
カットパターンを、図3に示す、繊維長さLが24mmで、切込と強化繊維とのなす角度が14°の連続的なカットパターンとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。切込プリプレグシートの取り扱い性はポリエチレンフィルムが切込に沿って短冊状に切断されており、セロハンテープが接着されたポリエチレンフィルム片のみが剥がれるため、切込プリプレグに密着した全てのポリエチレンフィルム片を剥がすのに手間を要した。切込プリプレグの成形時伸張率は2.1であり、伸張成形品の表面品位は切込の開口に加え、繊維が流動してうねりが見えていた。伸張成形品の力学特性は、引張弾性率46GPa、引張強度710MPaとなった。
カットパターンを、図4に示す、切込が強化繊維を横切る方向へ断続的な切込が設けられており、断続的な切込が直線状かつ平行に挿入されて列を形成し、列間の距離が2.9mm、繊維長さLは24mm、Wsは1mm、強化繊維と切込のなす角度θが14°であるカットパターンとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
カットパターンを、図5に示す、切込が強化繊維を横切る方向へ断続的な切込が設けられており、断続的な切込が直線状に挿入され、強化繊維と切込のなす角度θの絶対値が実質的に同一であり、正と負の角度となる切込が略半数ずつあり、任意の切込と近接する切込のうち、θの正負が同一である切込よりも最短距離が近いθの正負が異なる切込が4つ存在するカットパターンであり、繊維長さLを24mm、θを±14°、Wsを1mmとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
カットパターンを、図6に示す、実施例1と同じカットパターンとした以外は実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
切込が強化繊維を横切る方向へ断続的な切込が設けられており、断続的な切込が直線状かつ平行に挿入されて列を形成し、列間の距離を8.5mm、強化繊維と切込のなす角度θを45°、繊維長さLを24mm、Wsを1.0mmとしたカットパターンとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
切込が強化繊維を横切る方向へ断続的な切込が設けられており、断続的な切込が直線状かつ平行に挿入されて列を形成し、列間の距離を12mm、強化繊維と切込のなす角度θを90°、繊維長さLを24mm、Wsを20mmとしたカットパターンとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
切込が強化繊維を横切る方向へ断続的な切込が設けられており、断続的な切込が設けられており、断続的な切込が直線状かつ平行に挿入されて列を形成し、列間の距離を8.5mm、強化繊維と切込のなす角度θを45°、繊維長さLを24mm、Wsを17.0mmとしたカットパターンとした以外は、実施例2と同様にして、切込プリプレグシートを作製し、同様の評価を行った。
実施例1で用いたプリプレグシートに切込を挿入せずに使用した。実施例1と同様、成形時伸張率、伸張成形品の表面品位、力学特性を評価した。プリプレグの成形時伸張率は1.1、伸張成形を試みたが金型の大きさまで伸張することができておらず、樹脂が周囲に染み出して表面の樹脂が不足して品位は低くなった。伸張成形品の力学特性は、引張弾性率48GPa、引張強度920MPaであった。
2:プリプレグ第2の層
3:切込
4:切込プリプレグ
5:繊維方向
6:繊維直交方向
7:断続的な切込
8:連続的な切込
9:断続的な斜め切込(繊維方向に対して正の角度)
10:断続的な斜め切込(繊維方向に対して負の角度)
11:断続的な切込の列
12:L字に賦形されたプリプレグ積層体
13:L字片面型
14:コーナー部内径
15:L字部材の切り出し断面
16:刃
17:テープ状支持体A
18:テープ状支持体B
Claims (15)
- 樹脂組成物が含浸した強化繊維を含む層を有するプリプレグであって、複数の切込によって少なくとも一部が繊維長さ(L)10〜300mmの強化繊維で構成され、かつ、強化繊維の体積含有率Vfが45〜65%の範囲内である、切込プリプレグ。
- 強化繊維からなる第1の層と、樹脂組成物が含浸した強化繊維を含む第2の層とからなるプリプレグであって、第1の層の両側に第2の層が設けられ、プリプレグ中における樹脂組成物の含浸率が10〜90%である、請求項1に記載の切込プリプレグ。
- 第2の層が、熱硬化性樹脂組成物を含浸した強化繊維からなるA層と、熱可塑性樹脂の粒子または繊維を含むB層とからなり、B層は切込プリプレグ表面に面している、請求項2に記載の切込プリプレグ。
- 前記切込プリプレグが、室温にて切込プリプレグの一方の表面に10水柱cmの圧力で水を接触させた場合に、1分以内に反対の面から水が染み出すものである、請求項1〜3のいずれかにに記載の切込プリプレグ。
- 切込プリプレグが、該切込プリプレグを積層し以下に示す方法にて形成した切込プリプレグ積層体の厚みが、当該切込プリプレグ積層体を加熱して固化させ、繊維強化プラスチックとした際の厚みに対して5〜50%厚いものである、請求項1〜4のいずれかに記載の切込プリプレグ。
(切込プリプレグ積層体の形成方法)片面型とバグフィルムにより密閉空間を形成し、当該密閉空間に切込プリプレグを積層した積層体を配置し、室温にて密閉空間を真空引きして大気圧との差圧で切込プリプレグを積層した積層体を加圧して切込プリプレグ積層体を形成する。 - 切込プリプレグが、該切込プリプレグを16〜32層積層し以下に示す曲面成形を行って得られた繊維強化プラスチックの曲面の部分に実質的にボイドが含まれないものである、請求項1〜5のいずれかに記載の切込プリプレグ。
(曲面成形)曲率半径10mmの曲面を有する雌型とバグフィルムにより密閉空間を形成し、当該密閉空間に切込プリプレグを16〜32層積層した積層体を配置し、密閉空間を真空引きして大気圧との差圧で前記切込プリプレグを16〜32層積層した積層体を加圧しながら、加熱して固化させ繊維強化プラスチックを得る。 - 切込プリプレグの少なくとも一部に強化繊維を横切る方向へ断続的な切込が複数設けられており、前記切込を切込プリプレグの面内における強化繊維の垂直方向に投影した投影長さWsが30μm〜1.5mmであり、断続的な切込同士によって、強化繊維の長手方向に囲まれる領域において実質的に強化繊維のすべてが切込により分断されている、請求項1〜6のいずれかに記載の切込プリプレグ。
- 切込と強化繊維とのなす角度をθとしたとき、θの絶対値が2〜25°の範囲内である、請求項1〜7のいずれかに記載の切込プリプレグ。
- 切込プリプレグの少なくとも一部に強化繊維を横切る方向へ断続的な切込が複数設けられており、断続的な切込が直線状かつ平行に挿入されて列を形成し、列間の距離Xが1〜5mmの範囲内である、請求項1〜8のいずれかに記載の切込プリプレグ。
- 切込プリプレグの少なくとも一部に強化繊維を横切る方向へ断続的な切込が複数設けられており、断続的な切込が直線状に挿入され、θの絶対値が実質的に同一であり、正と負の角度となる切込が略半数ずつである、請求項1〜9のいずれかに記載の切込プリプレグ。
- 任意の1つの切込Aに着目したとき、該切込と近接する切込のうち、θの正負が同一である最も近い切込Bよりも切込Aとの最短距離が近いθの正負が異なる切込Cが4つ以上存在する、請求項10に記載の切込プリプレグ。
- 切込プリプレグの少なくとも一部に強化繊維を横切る方向へ断続的な切込が複数設けられており、断続的な切込が直線かつ実質的に同一の長さYで挿入され、近接する切込同士の最短距離が切込の長さYよりも長い、請求項1〜11のいずれかに記載の切込プリプレグ。
- 切込プリプレグの少なくとも一部に強化繊維を横切る方向へ断続的な切込が複数設けられており、断続的な切込が直線かつ実質的に同一の長さYで挿入され、同一直線状の近接する切込間距離がYの3倍より大きい、請求項1〜12のいずれかに記載の切込プリプレグ。
- 請求項1〜13のいずれかに記載の切込プリプレグの片面にテープ状支持体Aが接触するように積層された切込プリプレグシートであって、テープ状支持体Aの厚み方向に、テープ状支持体Aの切込プリプレグと接触する面から5〜75%の範囲で切込プリプレグの切込と連続した切込を有する、切込プリプレグシート。
- テープ状支持体Aとは接しない側の切込プリプレグの面に、テープ状支持体Bが接触するように積層された切込プリプレグシートであって、テープ状支持体Bは、切込プリプレグの切込と連続した切込が厚み方向に貫通して存在している、請求項14に記載の切込プリプレグシート。
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