KR101909726B1 - Slurry for manufacturing carbon fiber reinforced plastic and method of manufacturing carbon fiber reinforced plastic using the same - Google Patents

Abstract

One embodiment of the present invention is a thermoplastic resin powder having a particle diameter of 1 to 50 占 퐉; A binder powder having a particle diameter of 0.1 to 30 占 퐉; And a solvent; And a slurry for producing carbon fiber-reinforced plastics.

Description

Technical Field [0001] The present invention relates to a slurry for manufacturing a carbon fiber-reinforced plastic, and a method for manufacturing a carbon fiber-reinforced plastic using the slurry. BACKGROUND ART < RTI ID = 0.0 >

One embodiment of the present invention relates to a slurry for manufacturing carbon fiber-reinforced plastics and a method for producing carbon fiber-reinforced plastics using the same.

BACKGROUND ART In general, continuous carbon fiber reinforced thermoplastic has a reinforced fiber such as glass fiber or carbon fiber in a continuous phase in a plastic having a relatively low mechanical strength. Reinforced plastics have a length of 5 to 50 mm, such as Short Fiber-reinforced Thermoplastics or Long Fiber-reinforced Thermoplastics (LFT) or Glass Mat-reinforced Thermoplastics Compared to long-fiber reinforced plastics, it has excellent mechanical strength, rigidity and impact performance.

Continuous fiber reinforced plastics are also highly flexible and can be woven in either unidirectional or both directions through which woven continuous fiber reinforced plastic structures can be applied to products that require a variety of mechanical performances.

The continuous fiber-reinforced plastic is usually produced by a pultrusion method, a commingle method, a hot pressing method, or the like.

In addition, in the prior art, US 1983-459551 discloses a technique of melting a thermoplastic resin and then coating the carbon fiber by immersion. However, when the thermoplastic resin is immersed after melting the thermoplastic resin, it is difficult to maintain a uniform thickness and width after immersion due to the thin thickness of the woven carbon fiber bundle, and the surface condition is poor.

And to provide a slurry for manufacturing carbon fiber-reinforced plastic and a method for manufacturing carbon fiber-reinforced plastic using the same.

The slurry for preparing a carbon fiber-reinforced plastic according to an embodiment of the present invention comprises a thermoplastic resin powder having a particle diameter of 1 to 50 mu m; A binder powder having a particle diameter of 0.1 to 30 占 퐉; And a solvent; And a slurry for producing carbon fiber-reinforced plastics.

The slurry may be a slurry for producing carbon fiber-reinforced plastics containing 20 to 40 wt% of a thermoplastic resin powder, 5 to 10 wt% of a binder powder, and a residual solvent, based on 100 wt% of the slurry.

The slurry may further comprise a dispersant, a thickener, and an antifoaming agent.

A dispersing agent in an amount of 0.1 to 1.0 part by weight, a thickener in an amount of 0.1 to 1.0 part by weight, and a defoaming agent in an amount of 0.1 to 1.0 part by weight based on 100 parts by weight of the slurry.

The viscosity of the slurry may range from 5000 to 15000 cps.

The thermoplastic resin may be a polyamide type, a polyethylene type, a polyester type, a polypropylene type, a polyetheretherketone, a polycarbonate, a polyethylene terephthalate (PET), a polyphenylene sulfide (PPS) or a combination thereof.

The binder may be a co-polyamide, a polyester, or a combination thereof.

According to another aspect of the present invention, there is provided a method of manufacturing a carbon fiber-reinforced plastic, comprising: preparing a carbon substrate including at least one carbon fiber; Thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent; Coating the prepared slurry on the carbon substrate; Drying the coated carbon substrate to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; And hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic; Wherein the carbon fiber-reinforced plastic material is a carbon fiber-reinforced plastic material.

The carbon base material comprising at least one carbon fiber may be a fiber bundle in which a plurality of carbon fibers are arranged in a uni-directional arrangement or biaxial. The fiber bundles arranged in the bi-axial direction may be fiber bundles arranged at 0 degree and 90 degrees.

Preparing a carbon substrate comprising at least one carbon fiber; , The carbon substrate may be broadened under hot air and vacuum conditions at 100 to 250 ° C.

In addition, the width of the carbon fibers may be increased by 2 to 10 times as compared with the width before the carbon fiber is widened.

Thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent; , The slurry may include a thermoplastic resin powder having a particle diameter of 1 to 50 mu m, a binder powder having a particle diameter of 0.1 to 30 mu m, and a solvent.

The slurry may contain 20 to 40 wt% of the thermoplastic resin powder, 5 to 10 wt% of the binder powder, and the remaining solvent, based on 100 wt% of the slurry.

The viscosity of the slurry may range from 5000 to 15000 cps.

Coating the prepared slurry on the carbon substrate; , A method of spraying the slurry onto the carbon substrate may be used. A method of impregnating the carbon base material into the slurry may also be used.

Drying the coated carbon substrate to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; , The coated carbon substrate may be dried at 150-200 [deg.] C for 10 seconds to 30 seconds.

Hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic; , The thermoplastic prepreg can be hot-pressed at a pressure of 1 to 10 MPa.

Hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic; , The thermoplastic prepreg can be hot-pressed at 200 to 400 DEG C for 1 to 10 minutes.

Wherein the volume of pores in the carbon fibers is 0.1 to 0.5% by volume based on 100% by volume of the carbon fiber-reinforced plastic.

According to one embodiment of the present invention, the impregnability of the resin is improved, thereby maximizing the volume fraction of the continuous carbon fibers. In addition, various types of carbon fiber-reinforced plastic having high strength and light weight can be obtained by unidirectionally arranging or weaving prepregs and then hot pressing.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an SEM photograph of a conventional powder (200 μm) of polyamide 6 and a polyamide 6 powder (30 μm) prepared according to an embodiment of the present invention.
2 shows a process for producing a slurry for manufacturing carbon fiber-reinforced plastics according to an embodiment of the present invention.
FIG. 3 illustrates a prepreg obtained in a method of producing a carbon fiber-reinforced plastic according to another embodiment of the present invention.
4 shows an example of a method of manufacturing a carbon fiber-reinforced plastic according to another embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention, and the manner of achieving them, will be apparent from and elucidated with reference to the embodiments described hereinafter in conjunction with the accompanying drawings. However, it is to be understood that the present invention is not limited to the disclosed embodiments, but may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. It is intended that the disclosure of the present invention be limited only by the terms of the appended claims. Like reference numerals refer to like elements throughout the specification.

Thus, in some embodiments, well-known techniques are not specifically described to avoid an undesirable interpretation of the present invention. Unless defined otherwise, all terms (including technical and scientific terms) used herein may be used in a sense commonly understood by one of ordinary skill in the art to which this invention belongs. Whenever a component is referred to as "including" an element throughout the specification, it is to be understood that the element may include other elements, not the exclusion of any other element, unless the context clearly dictates otherwise. Also, singular forms include plural forms unless the context clearly dictates otherwise.

The slurry for preparing a carbon fiber-reinforced plastic according to an embodiment of the present invention comprises: a thermoplastic resin powder having an average particle diameter of 1 to 50 占 퐉; A binder powder of 0.1 to 30 占 퐉; And a solvent; And a slurry for producing carbon fiber-reinforced plastics. More specifically, the slurry may further comprise a dispersant, a thickener, and a defoamer.

The particle size in this specification means the average diameter of the spherical material present in the unit of measurement. If the material is an acetal, it means the diameter of the sphere calculated by approximating the spherical material to the spherical shape.

More specifically, when the thermoplastic resin powder and the powder of the binder do not satisfy the above-described size range, it may be difficult to produce a slurry having a desired viscosity and degree of dispersion. In addition, when the particle size of the resin powder in the slurry is large, it is possible to precipitate without being dispersed well.

More specifically, the slurry may comprise 20 to 40% by weight of the thermoplastic resin powder, 5 to 10% by weight of the binder powder, and the remaining solvent, based on 100% by weight of the slurry.

The dispersant may be 0.1 to 1.0 parts by weight based on 100 parts by weight of the slurry, 0.1 to 1.0 parts by weight of a thickener, and 0.1 to 1.0 part by weight of a defoaming agent.

Hereinafter, the reason for limiting the content of the component will be described.

20 to 40% by weight of the thermoplastic resin powder, 5 to 10% by weight of the binder powder, and the remaining solvent may be contained relative to 100% by weight of the slurry.

More specifically, when the amount of the thermoplastic resin powder is more than 40% by weight, impregnation may not be easy because the resin powder is aggregated in a cake form instead of a slurry form. If it is less than 20% by weight, the impregnation may not be easy because the weight of the thermoplastic resin powder is not sufficient.

More specifically, the thermoplastic resin may be selected from the group consisting of polyamide-based, polyethylene-based, polyester-based, polypropylene-based, polyetheretherketone, polycarbonate, polyethylene terephthalate (PET), polyphenylene sulfide Combinations thereof. However, the present invention is not limited thereto, and includes any thermoplastic resins which can be commonly used.

When the binder powder is contained in the above range, it can be melted at a hot air drying temperature of 200 ° C or more to easily serve as a bonding agent between the matrix polyamide 6 (PA 6) powder and the carbon fiber filament. More specifically, the binder may be, but is not limited to, Co-polyamide, polyester, or a combination thereof.

The balance with respect to 100 wt% of the slurry can be a solvent and the solvent can be water. However, the present invention is not limited thereto.

The dispersant may be 0.1 to 1.0 part by weight, the thickener may be 0.1 to 1.0 part by weight, and the defoaming agent may be 0.1 to 1.0 part by weight based on 100 parts by weight of the slurry.

More specifically, when the dispersing agent is contained in the above range, a uniform dispersing effect can be obtained. In addition, the above-mentioned dispersing agent can be used as a dispersing agent which is commonly used.

In addition, when the thickener is contained in the above-mentioned range, an effect of preventing sedimentation of the resin powder may be exhibited. In addition, the thickener may be any commonly used thickener.

When the antifoaming agent is contained in the above-mentioned range, the effect of removing air bubbles may be exhibited. More specifically, the defoaming agent is applicable to both defoaming agents commonly used.

The viscosity of the slurry containing such components can be from 5000 to 15000 cps. When the viscosity of the slurry is in the above range, it can have an excellent impregnation effect.

According to another aspect of the present invention, there is provided a method of manufacturing a carbon fiber-reinforced plastic, comprising: preparing a carbon substrate including at least one carbon fiber; Thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent; Coating the prepared slurry on the carbon substrate; Drying the coated carbon substrate to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; And hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic; Wherein the carbon fiber-reinforced plastic material is a carbon fiber-reinforced plastic material.

More specifically, there is provided a method of manufacturing a carbon fiber, comprising: preparing a carbon substrate comprising the at least one carbon fiber; , The carbon base material including the at least one carbon fiber may be a fiber bundle in which a plurality of carbon fibers are arranged in a uni-directional arrangement or a biaxial direction. More specifically, the fiber bundles arranged in Bi-axial may be fiber bundles arranged at 0 degree and 90 degrees.

In addition, the carbon substrate can be broadened under hot air and vacuum conditions at 100-250 占 폚. Accordingly, the width of the carbon fiber may be increased by 2 to 10 times as much as the width before the carbon fiber is widened.

Preparing a carbon substrate comprising the at least one carbon fiber; , The reason why the carbon base material is widened is to increase the impregnation rate of the slurry and to obtain the effect of uniformly impregnating the carbon fiber filament.

Then, a thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent; . ≪ / RTI >

The slurry in the step is a thermoplastic resin powder having an average particle diameter of 1 to 50 占 퐉; A binder powder having a particle diameter of 0.1 to 30 占 퐉; And a solvent.

The slurry may contain 20 to 40% by weight of the thermoplastic resin powder, 5 to 10% by weight of the binder powder, and the remaining solvent, based on 100% by weight of the slurry.

More specifically, the slurry may further contain a dispersing agent, a thickener, and a defoaming agent. A dispersant having a content of 0.1 to 1.0 part by weight, a thickener having a content of 0.1 to 1.0 part by weight, and a defoaming agent having a content of 0.1 to 1.0 part by weight, .

The reason for limiting the content of the slurry is as described above.

The viscosity of the slurry containing such components can be from 5000 to 15000 cps. When the viscosity of the slurry is in the above range, it can have an excellent impregnation effect.

Coating the prepared slurry on the carbon substrate; Can be performed.

More specifically, the coating may comprise spraying the slurry onto the carbon substrate. More specifically, the method may include a method of impregnating the carbon base material into the slurry.

In the above method, when the slurry is sprayed onto the carbon substrate, the slurry can be coated while the wider carbon fiber bundle passes through the spray application zone. Therefore, since the surface can be uniformly applied in the continuous widening process, it may be advantageous to impregnate the ultra-slim wide-width carbon fiber bundle at a high speed.

More specifically, the method disclosed in FIG. 4 shows a case where a slurry is impregnated using a spraying method, in the method of manufacturing a carbon fiber-reinforced plastic according to an embodiment of the present invention.

On the other hand, when the carbonaceous substrate is impregnated in the slurry, the slurry can be coated while the wider carbon fiber bundle passes through the bath containing the slurry. Therefore, there is an advantage that the amount of impregnation can be increased as compared with the spraying method while passing the carbon substrate through the bath.

Thereafter, the coated carbon substrate is dried to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; As shown in FIG.

The coated carbon substrate may be dried at 150-200 [deg.] C for 10 seconds to 30 seconds. In the case of drying in the temperature and time range, the resin powder for the binder is melted and a prepreg in the form of a carbon substrate and a thermoplastic resin powder bonded together can be obtained.

Finally, hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic.

Hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic; , The thermoplastic prepreg can be hot-pressed to a pressure of 1 to 10 MPa.

The thermoplastic prepreg may vary depending on the type of resin, but may typically be hot-pressed at 200 to 400 ° C for 1 to 10 minutes.

The carbon fiber-reinforced plastic obtained by heat-treating at a temperature within the above range may have a volume of voids in the carbon fiber of 0.1 to 0.5% by volume based on 100% by volume of the entirety of the carbon fiber-reinforced plastic.

Hereinafter, the embodiment will be described in detail. The following examples are illustrative of the present invention only and are not intended to limit the scope of the present invention.

[ Example ]

After preparing a carbon fiber bundle of MRC 50K, the carbon fiber was widened at a temperature of 200 캜 and a vacuum condition to a width of 60 mm.

Domestic polyamide 6 pellets were milled at an average particle size of 30 mu m using a hammer-type freeze grinder under a liquid nitrogen atmosphere, which was a modification of a ceramic grinder manufactured by KURIMOTO Co., Ltd. (KML) to prepare a thermoplastic powder. Further, the copolyamide was pulverized to an average particle size of 15 mu m to prepare a binder powder.

FIG. 1 is a SEM photograph showing a conventional powder (200 μm) of polyamide 6 and a polyamide 6 powder (30 μm) prepared according to an embodiment of the present invention.

A slurry containing 30% by weight of the thermoplastic resin powder, 7% by weight of the binder powder, and the remainder was prepared with respect to 100% by weight of the whole slurry.

0.5 part by weight of a dispersing agent (DISPEXCEL-LB 1024) from Nopco Korea, 0.6 part by weight of a thickener (SN-THICKENER 623N) from Korea, and a defoamer (DAPPO SN-367) 0.6 The slurry was further prepared in a weight portion. The slurry production process is as described in Fig.

The carbon fiber bundle having a width of 60 mm prepared above was passed through a bath containing the slurry to impregnate the carbon fiber with the slurry.

Thereafter, it was dried at 150 DEG C for 30 seconds while passing through the hot wind section. By the above drying, the solvent was dried and the binder powder was melted.

As a result, the thermoplastic resin powder (polyamide 6) adhered to the carbon fiber filament to obtain a prepreg. The shape of the obtained prepreg is as shown in Fig.

The prepreg was subjected to hot press treatment at 300 占 폚 for 5 minutes under a pressure of 10 MPa to obtain a carbon fiber-reinforced plastic.

The obtained carbon fiber-reinforced plastic was evaluated for flexural physical properties according to the ASTM 790 standard. As a result, it was confirmed that the flexural strength value was 1,050 Mpa.

While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, You will understand.

It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive. The scope of the present invention is defined by the appended claims rather than the detailed description, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be interpreted as being included in the scope of the present invention .

Claims (15)

delete delete delete delete delete delete delete delete delete delete Preparing a carbon substrate comprising at least one carbon fiber;
Thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent;
Coating the prepared slurry on the carbon substrate;
Drying the coated carbon substrate to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; And
Hot-pressing the thermoplastic prepreg to obtain a carbon fiber-reinforced plastic,
Coating the prepared slurry on the carbon substrate; Quot;
A method of spraying the slurry onto the carbon base material is used,
Wherein the thermoplastic resin is selected from the group consisting of polyamide, polyethylene, polyester, polypropylene, polyetheretherketone, polycarbonate, polyethylene terephthalate (PET), polyphenylene sulfide (PPS)
The thermoplastic resin has a particle diameter of 1 to 50 탆,
The binder may be a co-polyamide, a polyester or a combination thereof,
Thermoplastic resin powder; Binder powder; And preparing a slurry for producing carbon fiber-reinforced plastics comprising a solvent,
The solvent is water,
Drying the coated carbon substrate to obtain a thermoplastic prepreg impregnated with a carbon-based material therein; and performing the carbon fiber-reinforced plastic material at 150 to 200 ° C for 10 seconds to 30 seconds.
12. The method of claim 11,
Thermoplastic resin powder; Binder powder; Preparing a slurry for manufacturing a carbon fiber-reinforced plastic including a solvent; in,
Wherein the slurry comprises a binder powder having a particle diameter of 0.1 to 30 占 퐉, and a solvent.
13. The method of claim 12,
Wherein the slurry comprises 20 to 40 wt% of a thermoplastic resin powder, 5 to 10 wt% of a binder powder, and a remaining solvent, based on 100 wt% of the slurry.
14. The method of claim 13,
Wherein the slurry has a viscosity of 5000 to 15000 cps.
12. The method of claim 11,
Coating the prepared slurry on the carbon substrate; Quot;
And the carbon substrate is impregnated in the slurry.

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