JPWO2018051445A1 - 複合材料の成形方法および複合材料 - Google Patents
複合材料の成形方法および複合材料 Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims abstract description 94
- 238000000034 method Methods 0.000 title claims abstract description 38
- 229920005989 resin Polymers 0.000 claims abstract description 189
- 239000011347 resin Substances 0.000 claims abstract description 189
- 239000010410 layer Substances 0.000 claims abstract description 79
- 239000002344 surface layer Substances 0.000 claims abstract description 66
- 238000000465 moulding Methods 0.000 claims abstract description 43
- 238000010030 laminating Methods 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 85
- 230000003014 reinforcing effect Effects 0.000 claims description 76
- 239000000835 fiber Substances 0.000 claims description 43
- 239000000758 substrate Substances 0.000 claims description 43
- 229920005992 thermoplastic resin Polymers 0.000 claims description 19
- 229920001187 thermosetting polymer Polymers 0.000 claims description 18
- 239000004753 textile Substances 0.000 claims description 9
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 8
- 239000004917 carbon fiber Substances 0.000 claims description 8
- 239000003365 glass fiber Substances 0.000 claims description 7
- 239000012779 reinforcing material Substances 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 description 29
- 239000011248 coating agent Substances 0.000 description 27
- 238000000576 coating method Methods 0.000 description 27
- 230000002787 reinforcement Effects 0.000 description 7
- 230000037303 wrinkles Effects 0.000 description 7
- 230000006866 deterioration Effects 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 238000007493 shaping process Methods 0.000 description 5
- 239000004743 Polypropylene Substances 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 239000004744 fabric Substances 0.000 description 3
- 238000010422 painting Methods 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical group C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 230000000452 restraining effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
- B29C70/0035—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties comprising two or more matrix materials
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/20—Making multilayered or multicoloured articles
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
- Mathematical Physics (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
12 織物材、
13 一方向材、
20 ベース層、
21 第1のプリプレグシート、
22 第1の強化基材、
23 母材樹脂(第1の樹脂)、
30 表面層、
30a 表面層の表面、最表面の第2のプリプレグシートの表面、最表面
31 第2のプリプレグシート、
32 第2の強化基材、
33 被覆樹脂(第2の樹脂)、
40 第1のプリプレグシートと第2のプリプレグシートとの間の界面、
100 成形装置、
150 制御部、
160 成形型、
161 上型、
162 下型、
163 温度調整部、
400 車体、
401 ルーフ、
402 ボンネット、
La 表面層の表面から第2の強化基材に達するまでの平均距離、
Lb 界面から第2の強化基材に達するまでの平均距離、
V1、V2 界面を含んだ単位体積。
Claims (18)
- 第1の強化基材に第1の樹脂が含浸され、ベース層を構成する第1のプリプレグシートを準備し、
第2の強化基材に第2の樹脂が含浸され、表面層を構成する第2のプリプレグシートを準備し、ここに、前記第2のプリプレグシートは、前記第1のプリプレグシートに積層したときに、前記第1のプリプレグシートと前記第2のプリプレグシートとの間の界面を含んだ単位体積あたりにおいて、前記第2のプリプレグシートにおける前記第2の樹脂の量の方が、前記第1のプリプレグシートにおける前記第1の樹脂の量よりも多く、
前記第1のプリプレグシートの表面の少なくとも一部に前記第2のプリプレグシートを積層し、
積層した前記第1のプリプレグシートと前記第2のプリプレグシートとを加熱して硬化させ、前記第1のプリプレグシートによって構成される前記ベース層の表面に、前記第2のプリプレグシートによって構成される前記表面層を一体的に形成する、複合材料の成形方法。 - 前記第2の強化基材は、ガラス繊維からなる、請求項1に記載の複合材料の成形方法。
- 前記第2の強化基材は、繊維を織り込んだ織物材である、請求項1または請求項2に記載の複合材料の成形方法。
- 前記第2の樹脂は、熱可塑性樹脂である、請求項1〜3のいずれか1項に記載の複合材料の成形方法。
- 最表面の前記第2のプリプレグシートに関して、最表面と前記第2の強化基材との間の領域における前記第2の樹脂の量は、当該第2のプリプレグシートの裏面と前記第2の強化基材との間の領域における前記第2の樹脂の量よりも多い、請求項1〜4のいずれか1項に記載の複合材料の成形方法。
- 前記第1の強化基材は、炭素繊維の長繊維からなる、請求項1〜5のいずれか1項に記載の複合材料の成形方法。
- 前記第1の強化基材は、繊維が一方向に引き揃えられた一方向材である、請求項1〜6のいずれか1項に記載の複合材料の成形方法。
- 前記第1の樹脂は、熱硬化性樹脂である、請求項1〜7のいずれか1項に記載の複合材料の成形方法。
- 第1の強化基材と第1の樹脂とを含むベース層と、
前記ベース層の表面の少なくとも一部に一体的に形成され、第2の強化基材と第2の樹脂とを含む表面層と、を有し、
前記ベース層と前記表面層との間の界面を含んだ単位体積あたりにおいて、前記表面層における前記第2の樹脂の量の方が、前記ベース層における前記第1の樹脂の量よりも多い、複合材料。 - 前記ベース層と前記表面層とが積層された断面において、前記表面層における前記第2の樹脂が前記界面上に存在する範囲は、前記ベース層における前記第1の樹脂が前記界面上に存在する範囲よりも大きい、請求項9に記載の複合材料。
- 前記第2の強化基材は、ガラス繊維からなる、請求項9または請求項10に記載の複合材料。
- 前記第2の強化基材は、繊維を織り込んだ織物材である、請求項9〜11のいずれか1項に記載の複合材料。
- 前記第2の樹脂は、熱可塑性樹脂である、請求項9〜12のいずれか1項に記載の複合材料。
- 前記表面層に関して、表面と前記表面に面する前記第2の強化基材との間の領域における前記第2の樹脂の量は、前記ベース層との間の前記界面と前記界面に面する前記第2の強化基材との間の領域における前記第2の樹脂の量よりも多い、請求項9〜13のいずれか1項に記載の複合材料。
- 前記表面層の断面において、前記表面から前記表面に面する前記第2の強化基材に達するまでの平均距離は、前記界面から前記界面に面する前記第2の強化基材に達するまでの平均距離よりも大きい、請求項14に記載の複合材料。
- 前記第1の強化基材は、炭素繊維の長繊維からなる、請求項9〜15のいずれか1項に記載の複合材料。
- 前記第1の強化基材は、繊維が一方向に引き揃えられた一方向材である、請求項9〜16のいずれか1項に記載の複合材料。
- 前記第1の樹脂は、熱硬化性樹脂である、請求項9〜17のいずれか1項に記載の複合材料。
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