JPWO2019240094A1 - 複合素材、プリプレグ、炭素繊維強化成形体及び複合素材の製造方法 - Google Patents
複合素材、プリプレグ、炭素繊維強化成形体及び複合素材の製造方法 Download PDFInfo
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- JPWO2019240094A1 JPWO2019240094A1 JP2020525563A JP2020525563A JPWO2019240094A1 JP WO2019240094 A1 JPWO2019240094 A1 JP WO2019240094A1 JP 2020525563 A JP2020525563 A JP 2020525563A JP 2020525563 A JP2020525563 A JP 2020525563A JP WO2019240094 A1 JPWO2019240094 A1 JP WO2019240094A1
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Abstract
Description
[複合素材]
図1において、複合素材10は、複数の連続した炭素繊維11をまとめた炭素繊維束12を含む。各炭素繊維11の表面には、それぞれ構造体14が形成されており、構造体14の表面にサイジング剤(図示省略)が付着している。
重量比Rが0.0005以上であれば、炭素繊維強化成形体としたときに、上記のような構造体14による大きな拘束効果、複合領域での機械的エネルギーの大きな吸収効果を確実に得ることができ、CNT由来の特性が向上される。重量比Rが0.01以下であれば、構造体14へのマトリックス樹脂の樹脂含浸が確実になされる。また、重量比Rが0.001以上0.01以下であることがより好ましい。重量比Rが0.001以上であれば、ほぼ全ての炭素繊維11間にて構造体14(CNT17)がより確実に機能する。重量比Rが0.01以下であれば、構造体14へのマトリックス樹脂の樹脂含浸が確実になされ、また炭素繊維強化成形体におけるマトリックス樹脂の比率が低い場合であっても構造体14がより確実に機能する。さらに、重量比Rが0.001以上0.005以下であることがさらに好ましい。0.005以下であれば炭素繊維強化成形体におけるマトリックス樹脂の比率が低い場合であっても構造体14がより確実に機能する。
炭素繊維束12の各炭素繊維11のそれぞれにCNT17を付着させて構造体14を形成するには、CNT17が単離分散したCNT単離分散液(以下、単に分散液と称する)中に炭素繊維束12を浸漬し、分散液に機械的エネルギーを付与する。単離分散とは、CNT17が1本ずつ物理的に分離して絡み合わずに分散媒中に分散している状態をいい、2以上のCNT17が束状に集合した集合物の割合が10%以下である状態をさす。ここで集合物の割合が10%以上であると、分散媒中でのCNT17の凝集が促進され、CNT17の炭素繊維11に対する付着が阻害される。
分散液28は、例えば長尺のCNT(以下、材料CNTと称する)を分散媒に加え、ホモジナイザーや、せん断力、超音波分散機などにより、材料CNTを切断して所望とする長さのCNT17とするとともに、CNT17の分散の均一化を図ることで調製される。
図4において、プリプレグ31は、炭素繊維束12の構造体14が形成された炭素繊維11と、この炭素繊維束12に含浸された未硬化のマトリックス樹脂32とで構成される。プリプレグ31は、開繊された複合素材10にマトリックス樹脂32を含浸し、厚み方向に炭素繊維11が複数本並んだ帯状に形成される。複合素材10は、炭素繊維束12における炭素繊維11同士の絡み合いが実質的に存在しないものであるので、プリプレグ31を製造する際に、炭素繊維11を均一に拡げやすい。プリプレグ31の各炭素繊維11の繊維軸方向は、いずれも同一方向(図4の紙面垂直方向)に揃っている。プリプレグ31は、幅方向(開繊した方向)に複数の開繊した複合素材10を並べて形成することで、幅広のものとすることができる。
プリプレグ31を加圧しながらマトリックス樹脂32を加熱硬化することで炭素繊維強化成形体が作製される。複数枚のプリプレグ31を積層した積層体を加圧及び加熱することで、積層体を一体化した炭素繊維強化成形体とすることもできる。この場合、積層体における炭素繊維11の繊維軸方向は、プリプレグ31に相当する層ごとに任意の方向とすることができる。図5に示す炭素繊維強化成形体34では、プリプレグ31に相当する複数の層34aにおいて、炭素繊維11の繊維軸方向が上下の層34aで互いに直交するように形成されている。加熱及び加圧する手法は、プレス成形法、オートクレーブ成形法、バッギング成形法、シートワインディング法、フィラメントワインディング法および内圧成形法等を用いることができる。マトリックス樹脂32の体積含有率は、10〜40%が好ましく、15〜33%がより好ましい。マトリックス樹脂32は、弾性率が2〜5GPa程度であることが好ましい。
第2実施形態の複合素材は、構造体を構成する複数のCNTの一部を炭素繊維の表面に部分的に固定する複数の固定樹脂部を有するものである。以下に詳細を説明する他は、第1実施形態と同様であり、実質的に同じ部材には同一の符号を付して、その詳細な説明を省略する。
図6において、複合素材10Aは、複数の連続した炭素繊維11をまとめた炭素繊維束12を含む。各炭素繊維11の表面には、それぞれ構造体14が形成されている。各構造体14は、複数のカーボンナノチューブ(以下、CNTと称する)17で構成される。また、複合素材10Aは、構造体14を構成する複数のCNT17の一部を炭素繊維11の表面に部分的に固定する複数の固定樹脂部38が設けられている。複合素材10Aは、典型的には炭素繊維強化成形体に用いられる。
上記複合素材10Aの製造工程は、構造体14の表面に第1サイジング剤を付着させる第1サイジング処理に代えて、固定樹脂部38を形成する第2サイジング処理を行なう他は、第1実施形態と同じである。すなわち、炭素繊維束12は、分散液28(図2参照)中から引き出された後に乾燥された炭素繊維束12に対して第2サイジング処理を行うことで、固定樹脂部38を形成する。第2サイジング処理は、固定樹脂部38となる材料やその形態に応じた処理とすることができる。
この例におけるプリプレグ31(図5参照)は、炭素繊維束12の構造体14及び固定樹脂部18が形成された炭素繊維11と、この炭素繊維束12に含浸された未硬化のマトリックス樹脂19とで構成される。また、このプリプレグ31を加圧しながらマトリックス樹脂32を加熱硬化することで炭素繊維強化成形体が作製される。この例におけるプリプレグ31及び炭素繊維強化成形体およびその作製手法は、各炭素繊維11に固定樹脂部38が形成されている他は、第1実施形態のものと同様である。
(均一性の評価)
A.SEM観察
第1サイジング処理及び乾燥後の炭素繊維束12の一部を切り出し、第1サイジング剤を除去してから、炭素繊維11を取得した。取得した各炭素繊維11に複数のCNT17が均一に分散して付着していることをSEM観察して確認した。
次に重量比Rによる均一性の評価を行った。第1サイジング処理後の炭素繊維束12の長さ1mの評価範囲をほぼ均等に網羅するように10ヶ所の測定部位を設定した。10ヶ所の測定部位は、評価範囲の両端とその間の8カ所とし、各測定部位のそれぞれについて3mm(約2mg)程度にそれぞれ炭素繊維束12(12000本の炭素繊維11)を切り出して測定試料A1〜A10とした。測定試料A1〜A10のそれぞれについて下記のようにして重量比Rを求めた。
(2)測定試料を投入する前の測定液の重量と測定試料を含む測定液の重量との差分を計測し、これを測定試料の重量、すなわち炭素繊維11のCF重量Waとその炭素繊維11に付着しているCNT17のCNT重量Wbとの和(Wa+Wb)とする。
(3)測定試料を含む測定液に超音波振動を与えて、炭素繊維11からそれに付着しているCNT17を完全に分離し、CNT17を測定液中に分散する。
(4)吸光光度計を用いて,CNT17が分散している測定液の吸光度(透過率)を測定する。吸光光度計による測定結果と、予め作成しておいた検量線とから測定液中のCNT17の濃度(以下、CNT濃度という)を求める。CNT濃度をC、測定液の重量をW1、この測定液に含まれるCNT17の重量W2としたときに、「C=W2/(W1+W2)」で与えられる重量パーセント濃度である。
(5)得られたこのCNT濃度と測定試料を投入する前の測定液の重量とから測定液中のCNT17の重量(Wb)を求める。
(6)(2)で求めたCF重量WaとCNT重量Wbの和(Wa+Wb)と、CNT17の重量(Wb)とから、重量比R(=Wb/(Wa+Wb))を算出する。
(振動減衰特性の評価)
実施例2として、図17に示すように、炭素繊維強化成形体として板状の試験片41を作製し振動減衰特性(制振性)を評価した。実施例2の試験片41は、幅D41を15mm、長さL41を200mm厚さt41を1.8mmとした。試験片41の作製では、200mm×15mmの長方形に切断した16枚のプリプレグ31を積層し、加圧しながら145℃で1時間加熱してマトリックス樹脂32を硬化させた。各プリプレグ31は、長手方向が炭素繊維11の繊維軸方向と一致するように切断した。したがって、試験片41は、その長手方向に全ての炭素繊維11の繊維軸方向(図中矢印A方向)が一致している。
(曲げ弾性率の変化特性)
実施例4では、図21に示すように、炭素繊維強化成形体として板状の試験片51を作製して曲げ弾性率の変化特性を評価した。試験片51は、長さL51を100mm、幅D51を15mm、厚さt51を1.8mmとした。試験片51の作製では、100mm×15mmの長方形に切断した16枚のプリプレグ31を積層し、加圧しながら145℃で1時間加熱してマトリックス樹脂32を硬化させた。試験片51は、実施例2の試験片41と同様に、その長手方向に全ての炭素繊維11の繊維軸方向(図中矢印A方向)が一致している。
(疲労特性の評価)
実施例5として、図22に示すように、炭素繊維強化成形体として板状の試験片61を作製し、3点曲げ疲労試験を行って曲げ疲労特性を評価した。実施例5の試験片61は、幅D61を15mm、長さL61を20mm以上、厚さt61を1.8mmとした。試験片61の作製では、長方形(L61×D61)に切断した16枚のプリプレグ31を積層し、加圧しながら145℃で1時間加熱してマトリックス樹脂32を硬化させた。各プリプレグ31は、長手方向が炭素繊維11の繊維軸方向と一致するように切断した。したがって、試験片61は、その長手方向に全ての炭素繊維11の繊維軸方向(図中矢印A方向)が一致している。
複合素材10Aからプリプレグ31を経て、実施例6で用いる炭素繊維強化成形体(試験片)を作製し、試験片に90°曲げ試験を行なった。
固定樹脂部38の個数割合Nと面積割合Sとの傾向を調べるため、炭素繊維11に対する固定樹脂部38の付着量が異なる11種類の試料を作製した。炭素繊維束及びそれに対する処理条件等は、サイジング液の希釈率以外は、実施例6の場合と同様とした。得られた各試料について、5μm四方の観察枠を設定して、個数割合Nと面積割合Sを調べた。
11 炭素繊維
12 炭素繊維束
14 構造体
17 カーボンナノチューブ
34 炭素繊維強化成形体
38 固定樹脂部
Claims (18)
- 炭素繊維と、
複数のカーボンナノチューブで構成され、前記カーボンナノチューブ同士が直接接触したネットワーク構造を形成するとともに、前記炭素繊維の表面に付着する前記カーボンナノチューブが前記炭素繊維の表面に直接付着した構造体と
を備え、
前記カーボンナノチューブは、屈曲部を有する曲がった形状である
ことを特徴とする複合素材。 - 一部の前記カーボンナノチューブを部分的に前記炭素繊維の表面に固定する複数の固定樹脂部を備え、
平面視した前記構造体の表面における、前記構造体の表面を覆う前記複数の固定樹脂部の面積の割合が6%以上45%以下の範囲内である
ことを特徴とする請求項1に記載の複合素材。 - 平面視した前記構造体の表面における、5μm四方当たりの前記固定樹脂部の個数が27個以上130個以下の範囲内であることを特徴とする請求項2に記載の複合素材。
- 前記構造体は、厚さが10nm以上300nm以下の範囲内であることを特徴とする請求項1ないし3のいずれか1項に記載の複合素材。
- 前記カーボンナノチューブは、長さが0.1μm以上10μm以下の範囲内であり、かつ直径が1nm以上15nm以下の範囲内であることを特徴とする請求項1ないし4のいずれか1項に記載の複合素材。
- 前記炭素繊維における当該炭素繊維の重量に対する当該炭素繊維に付着している前記カーボンナノチューブの重量の比である重量比が0.0005以上0.01以下の範囲内であることを特徴とする請求項1ないし5のいずれか1項に記載の複合素材。
- 前記炭素繊維の長さ1mの範囲における前記重量比の標準偏差が0.0005以下の範囲内であることを特徴とする請求項6に記載の複合素材。
- 複数の連続した前記炭素繊維により炭素繊維束が形成され、
前記炭素繊維束の前記炭素繊維のそれぞれに前記構造体が形成されていることを特徴とする請求項1ないし7のいずれか1項に記載の複合素材。 - 前記複数の炭素繊維にそれぞれ形成された前記構造体は、互いに独立した構造であり、一の前記炭素繊維の前記構造体と他の前記炭素繊維の前記構造体は、同じ前記カーボンナノチューブを共有しないことを特徴とする請求項8に記載の複合素材。
- 屈曲部を有する曲がった形状の複数のカーボンナノチューブが分散された分散液に超音波振動を印加する超音波工程と、
前記超音波振動が印加されている前記分散液に複数の連続した炭素繊維を有する炭素繊維束を開繊して浸漬し、前記炭素繊維に前記複数のカーボンナノチューブを付着させて、前記炭素繊維のそれぞれの表面に構造体を形成する付着工程と
を有することを特徴とする複合素材の製造方法。 - 前記付着工程の後に、開繊された前記炭素繊維束を未硬化の樹脂を分散媒に分散させた処理液に接触させてから、前記炭素繊維束から前記分散媒を蒸発させるとともに前記樹脂を硬化させて、前記構造体の一部の前記カーボンナノチューブを部分的に前記炭素繊維の表面に固定する複数の固定樹脂部を形成する固定樹脂部形成工程
を有することを特徴とする請求項10に記載の複合素材の製造方法。 - 前記超音波工程は、前記超音波振動の周波数が40kHz以上950kHz以下の範囲内であることを特徴とする請求項10または11に記載の複合素材の製造方法。
- 前記超音波振動の周波数をfs、前記カーボンナノチューブを付着させる前記炭素繊維束の部分が前記分散液に浸漬されている浸漬時間をTs秒としたときに、「Ts≧65000/fs」を満たすことを特徴とする請求項10ないし12のいずれか1項に記載の複合素材の製造方法。
- 請求項8または9に記載の複合素材と、
前記複合素材に含浸した状態のマトリックス樹脂と
を含むことを特徴とするプリプレグ。 - 請求項8または9に記載の複合素材と、
前記複合素材に含浸した状態で硬化しているマトリックス樹脂と
を含むことを特徴とする炭素繊維強化成形体。 - 請求項8または9に記載の複合素材と、
前記複合素材に含浸した状態で硬化しているマトリックス樹脂と
を含み、
長さ100mm、幅15mm、厚さ1.8mmの板状で幅方向が前記炭素繊維の繊維軸方向に一致する試験片として、JIS K 7074:1988に準拠した3点曲げ試験で5mm/分の試験速度で測定される曲げ弾性率に対して、同一の条件で試験速度を1000mm/秒にして測定される曲げ弾性率の増加率が2%以下であることを特徴とする炭素繊維強化成形体。 - 請求項8または9に記載の複合素材と、
前記複合素材に含浸した状態で硬化しているマトリックス樹脂と
を含み、
長さ200mm、幅15mm、厚さ1.8mmの板状で長手方向が前記炭素繊維の繊維軸方向に一致する試験片として、長手方向の一端の長さ50mmの範囲を挟持して水平に固定された前記試験片の他端を押し下げてから解放した後に測定される前記試験片の他端の変位量から得られる振幅の対数減衰率が0.029%以上であることを特徴とする炭素繊維強化成形体。 - 請求項8または9に記載の複合素材と、
前記複合素材に含浸した状態で硬化しているマトリックス樹脂と
を含み、
長さ20mm以上、幅15mm、厚さ1.8mmの板状で幅方向が前記炭素繊維の繊維軸方向に一致する試験片として、前記試験片の長手方向に20mmだけ離して配置された一対の支点で前記試験片を下側から支持した状態で、上方からの前記試験片の押圧と押圧の解除とを繰り返す片振りの3点曲げ疲労試験を行ったときに、応力振幅が1100MPa以上1300MPa以下の範囲内であるときの押圧時の荷重が0となるまでの押圧の繰り返し数が92000回以上1000000回以下の範囲内であることを特徴とする炭素繊維強化成形体。
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