KR101928196B1 - A composite article for automobile outer panels using recycled carbon fiber-reinforced plastics - Google Patents

A composite article for automobile outer panels using recycled carbon fiber-reinforced plastics Download PDF

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KR101928196B1
KR101928196B1 KR1020170078847A KR20170078847A KR101928196B1 KR 101928196 B1 KR101928196 B1 KR 101928196B1 KR 1020170078847 A KR1020170078847 A KR 1020170078847A KR 20170078847 A KR20170078847 A KR 20170078847A KR 101928196 B1 KR101928196 B1 KR 101928196B1
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layer
continuous
composite
fiber
carbon fibers
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KR1020170078847A
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Korean (ko)
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윤만석
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현대제철 주식회사
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—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
    • B32B5/22—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
    • B32B5/24—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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/521—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained by impregnation of carbon products with a carbonisable material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C04B35/83—Carbon fibres in a carbon matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength

Abstract

Disclosed is an invention relating to a composite molded body for an automobile outer panel using recycled carbon fibers. In one embodiment, the composite molded body comprises: a composite fiber layer; and a resin matrix impregnated in the composite fiber layer, wherein the composite fiber layer includes a short fiber mat, a first continuous fiber layer formed on one side of the short fiber mat, and a second continuous fiber layer formed on the other side of the short fiber mat. According to one embodiment of the present invention, provided is the composite molded body using the recycled carbon fibers excellent in mechanical strength and light weight properties.

Description

재생 탄소섬유를 이용한 자동차 외판용 복합 성형체 {A COMPOSITE ARTICLE FOR AUTOMOBILE OUTER PANELS USING RECYCLED CARBON FIBER-REINFORCED PLASTICS}TECHNICAL FIELD [0001] The present invention relates to a composite molded body for automobile exterior panels using recycled carbon fibers. BACKGROUND OF THE INVENTION [0002]

본 발명은 재생 탄소섬유를 이용한 복합 성형체에 관한 것이다. 더욱 상세하게는 재생 탄소섬유 강화 플라스틱 매트를 포함하여, 기계적 강도, 경량성 및 경제성이 우수하며, 표면에 고유의 직조 패턴을 구현하여 외관성이 우수한 재생 탄소섬유를 이용한 복합 성형체에 관한 것이다.The present invention relates to a composite molded body using recycled carbon fibers. More particularly, the present invention relates to a composite formed article comprising a regenerated carbon fiber-reinforced plastic mat, which is excellent in mechanical strength, light weight and economical efficiency, and which realizes a woven pattern inherent to the surface and has excellent appearance.

탄소섬유 강화 플라스틱(carbon fiber-reinforced plastics, CFRP)은 강도, 경량성, 강성 및 도전성 등이 우수하며, 특히 자동차 제조 분야에서 탄소섬유 강화 플라스틱을 사용하려는 시도가 활발히 이루어지고 있다. BACKGROUND OF THE INVENTION [0002] Carbon fiber-reinforced plastics (CFRP) are excellent in strength, light weight, rigidity and conductivity, and an attempt is particularly made to use carbon fiber reinforced plastics in the automobile manufacturing field.

이러한 탄소섬유 강화 플라스틱을 이용한 자동차 외판의 경우, 표면에 고유의 탄소섬유 직조 패턴이 드러나는 외판이 선호되고 있다.In the case of automobile shell plates using such carbon fiber-reinforced plastics, shell plates in which a unique carbon fiber weave pattern is revealed on the surface are preferred.

본 발명과 관련한 배경기술은 대한민국 등록특허공보 제10-1447136호(2014.07.07. 공고, 발명의 명칭: 섬유 강화 복합재의 성형방법)에 개시되어 있다.BACKGROUND ART [0002] The background art relating to the present invention is disclosed in Korean Patent Registration No. 10-1447136 (published on Jul. 31, 2017, entitled " Method of Forming Fiber-Reinforced Composite Material).

본 발명의 일 실시예에 의하면, 기계적 강도 및 경량성이 우수한 재생 탄소섬유를 이용한 복합 성형체를 제공하는 것이다.According to one embodiment of the present invention, there is provided a composite formed body using recycled carbon fibers excellent in mechanical strength and light weight.

본 발명의 일 실시예에 의하면, 생산 비용이 저렴하여 경제성이 우수한 재생 탄소섬유를 이용한 복합 성형체를 제공하는 것이다.According to one embodiment of the present invention, it is possible to provide a composite formed article using recycled carbon fibers which are inexpensive to produce and are excellent in economy.

본 발명의 일 실시예에 의하면, 표면에 고유의 직조 패턴을 구현하여, 외관성 및 심미성이 우수한 재생 탄소섬유를 이용한 복합 성형체를 제공하는 것이다.According to one embodiment of the present invention, there is provided a composite formed article using a regenerated carbon fiber having a surface-unique weave pattern and excellent appearance and aesthetics.

본 발명의 하나의 관점은 재생 탄소섬유를 이용한 복합 성형체에 관한 것이다. 한 구체예에서 상기 재생 탄소섬유를 이용한 복합 성형체는 복합섬유층; 및 상기 복합섬유층에 함침된 수지 매트릭스;를 포함하며, 상기 복합섬유층은 단섬유 매트층, 상기 단섬유 매트층의 일면에 형성된 제1 연속섬유층 및 상기 단섬유 매트층의 타면에 형성된 제2 연속섬유층을 포함한다.One aspect of the present invention relates to a composite formed article using recycled carbon fibers. In one embodiment, the composite formed article using the regenerated carbon fiber comprises a composite fiber layer; And a resin matrix impregnated in the composite fiber layer, wherein the composite fiber layer comprises a short fiber mat, a first continuous fiber layer formed on one side of the short fiber mat, and a second continuous fiber layer formed on the other side of the short fiber mat, .

한 구체예에서 상기 단섬유 매트층을 이루는 탄소 단섬유는 재생 탄소섬유를 포함할 수 있다.In one embodiment, the short carbon fibers constituting the short fiber mat layer may comprise regenerated carbon fibers.

한 구체예에서 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 능직, 평직, 주자직 또는 비크립핑 직물 형태일 수 있다. In one embodiment, the continuous carbon fibers comprising the first continuous fibrous layer and the second continuous fibrous layer may be in the form of twill, plain weave, trapezoidal or non-creped fabric.

한 구체예에서 상기 수지 매트릭스는 열경화성 수지 및 열가소성 수지 중 하나 이상을 포함하며, 상기 열경화성 수지는 에폭시 수지, 페놀 수지, 비닐에스테르 수지, 불포화 폴리에스테르 수지 중 하나 이상을 포함하고, 상기 열가소성 수지는 폴리올레핀, 폴리아미드, 폴리에스테르, 폴리페닐렌에테르, 폴리아세탈, 폴리카르보네이트, 폴리페닐렌술피드, 폴리이미드, 폴리에테르이미드, 폴리에테르술폰 및 폴리케톤 중 하나 이상 포함할 수 있다.In one embodiment, the resin matrix comprises at least one of a thermosetting resin and a thermoplastic resin, and the thermosetting resin includes at least one of an epoxy resin, a phenol resin, a vinyl ester resin, and an unsaturated polyester resin, , Polyamide, polyester, polyphenylene ether, polyacetal, polycarbonate, polyphenylene sulfide, polyimide, polyetherimide, polyether sulfone and polyketone.

한 구체예에서 상기 단섬유 매트층의 두께는 0.1~50mm 이고, 섬유면중량(FAW)은 150~600g/m2이며, 상기 제1 연속섬유층 및 제2 연속섬유층의 두께는 각각 0.1~30mm이며, 섬유면중량(FAW)은 각각 150~600g/m2 일 수 있다.In one embodiment, the thickness of the short fiber mat layer is 0.1 to 50 mm, the fiber surface weight (FAW) is 150 to 600 g / m 2 , the thicknesses of the first continuous fiber layer and the second continuous fiber layer are 0.1 to 30 mm , And the fiber surface weight (FAW) may be 150 to 600 g / m 2 , respectively.

한 구체예에서 상기 단섬유 매트층을 이루는 탄소 단섬유와, 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 필라멘트 수가 각각 3K~48K일 수 있다.In one embodiment, the short carbon fibers constituting the short fiber mat layer and the continuous carbon fibers constituting the first continuous fiber layer and the second continuous fiber layer may have a filament count of 3K to 48K, respectively.

한 구체예에서 상기 복합 성형체의 인장강도는 300MPa 이상일 수 있다.In one embodiment, the tensile strength of the composite formed article may be 300 MPa or more.

본 발명에 따른 재생 탄소섬유를 이용한 복합 성형체는 기계적 강도 및 경량성이 우수하고, 생산 비용이 저렴하여 경제성이 우수하며, 표면에 고유의 직조 패턴을 구현하여, 외관성 및 심미성이 우수할 수 있다.The composite molded article using the regenerated carbon fiber according to the present invention is excellent in mechanical strength and light weight, low in production cost and excellent in economy, and can realize excellent appearance and aesthetics by implementing a unique woven pattern on the surface .

도 1은 본 발명의 한 구체예에 따른 재생 탄소섬유를 이용한 복합 성형체를 나타낸 것이다.
도 2(a)는 본 발명에 따른 실시예 복합성형체의 표면을 나타낸 것이며, 도 2(b)는 본 발명에 대한 비교예 성형체의 표면을 나타낸 사진이다.
도 3(a)는 본 발명에 따른 실시예 복합성형체를 나타낸 것이며, 도 3(b)는 본 발명에 대한 비교예 성형체를 나타낸 사진이다.BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a composite molded body using a regenerated carbon fiber according to one embodiment of the present invention.
Fig. 2 (a) shows the surface of an example composite molded article according to the present invention, and Fig. 2 (b) shows a surface of a molded article of a comparative example according to the present invention.
FIG. 3 (a) shows an example composite article according to the present invention, and FIG. 3 (b) is a photograph showing a comparative example article according to the present invention.

이하, 본 발명을 상세히 설명한다. 이때, 본 발명을 설명함에 있어서 관련된 공지기술 또는 구성에 대한 구체적인 설명이 본 발명의 요지를 불필요하게 흐릴 수 있다고 판단되는 경우에는 그 상세한 설명은 생략할 것이다.Hereinafter, the present invention will be described in detail. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

그리고 후술되는 용어들은 본 발명에서의 기능을 고려하여 정의된 용어들로서 이는 사용자, 운용자의 의도 또는 관례 등에 따라 달라질 수 있으므로 그 정의는 본 발명을 설명하는 본 명세서 전반에 걸친 내용을 토대로 내려져야 할 것이다.It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to be exemplary, self-explanatory, allowing for equivalent explanations of the present invention.

재생 play 탄소섬유를Carbon fiber 이용한 복합  Composite used 성형체Shaped body

본 발명의 하나의 관점은 재생 탄소섬유를 이용한 복합 성형체에 관한 것이다. One aspect of the present invention relates to a composite formed article using recycled carbon fibers.

도 1은 본 발명의 한 구체예에 따른 복합 성형체를 나타낸 것이다. 상기 도 1을 참조하면, 상기 재생 탄소섬유를 이용한 복합 성형체(100)는 복합섬유층(10); 및 복합섬유층(10)에 함침된 수지 매트릭스(미도시);를 포함하며, 복합섬유층(10)은 단섬유 매트층(12), 단섬유 매트층(12)의 일면에 형성된 제1 연속섬유층(14) 및 단섬유 매트층(12)의 타면에 형성된 제2 연속섬유층(16)을 포함한다.1 shows a composite molding according to one embodiment of the present invention. Referring to FIG. 1, the composite formed body 100 using the regenerated carbon fibers comprises a composite fiber layer 10; And a resin matrix (not shown) impregnated into the composite fiber layer 10, wherein the composite fiber layer 10 comprises a short fiber mat layer 12, a first continuous fiber layer (not shown) formed on one surface of the short fiber mat layer 12 14 and a second continuous fibrous layer 16 formed on the other side of the short fiber mat layer 12.

본 명세서에서 상기 “단섬유”는 최대 길이가 0 초과 8mm 이하인 탄소섬유를 의미할 수 있다. 한 구체예에서 상기 단섬유 매트층은, 상기 단섬유가 불연속적으로 포함된 것일 수 있다. 예를 들면, 최대 길이가 0 초과 8mm 이하인 탄소섬유가 수지 매트릭스에 함침된 것을 사용할 수 있다. As used herein, the term "staple fibers" may refer to carbon fibers having a maximum length of greater than 0 and less than 8 mm. In one embodiment, the staple fiber mat layer may be one in which the staple fibers are discontinuously contained. For example, a carbon fiber having a maximum length of more than 0 mm and 8 mm or less impregnated with a resin matrix can be used.

한 구체예에서 상기 단섬유 매트층은 재생 탄소섬유를 포함할 수 있다. 상기 재생 탄소섬유를 적용한 단섬유 매트층은, 동일 크기의 연속 탄소 섬유를 사용한 탄소 섬유층에 비하여 원가가 약 70% 수준으로 경제성이 우수할 뿐 아니라, 밀도가 동일 크기의 연속 탄소 섬유에 비해 약 25% 수준으로 경량성 또한 확보할 수 있다.In one embodiment, the short fiber mat layer may comprise recycled carbon fibers. The short-fiber mat layer to which the regenerated carbon fiber is applied has a cost of about 70% as compared with the carbon fiber layer using the same size continuous carbon fibers, and the density is about 25 % And light weight can be ensured.

본 명세서에서, 상기 “연속된 탄소섬유”는, 8mm 초과의 길이를 가지는 연속적인 탄소섬유 또는, 탄소섬유 다발을 의미하는 것일 수 있다.As used herein, the term " continuous carbon fibers " may mean continuous carbon fibers or carbon fiber bundles having a length of more than 8 mm.

한 구체예에서 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 평직(plain weave), 능직(twill weave), 주자직(satin weave) 또는 비크립핑 직물(NCF) 형태일 수 있다. 한 구체예에서 상기 비크립핑 직물은, 원사를 한 층 또는 복수 개의 층으로 배열하여, 스티칭(stitching) 공정을 통해 직물로 제조하는 것으로, 배열된 원사를 고정하고 직물의 크림프(crimp)가 발생하지 않도록 한 것이다. 상기 비크립핑 직물은 일 방향(unidirection, UD) 또는 2축 방향(2-axial) 등의 배열을 가질 수 있다.In one embodiment, the continuous carbon fibers comprising the first continuous fiber layer and the second continuous fiber layer may be in the form of plain weave, twill weave, satin weave or non-creping fabric (NCF) . In one embodiment, the non-creeping fabric is fabricated from a fabric by arranging the yarn in one or more layers and stitching the fabric to form an array of yarns and crimping the fabric I will not. The non-creeping fabric may have an arrangement such as unidirection (UD) or biaxial (2-axial).

한 구체예에서 상기 수지 매트릭스는 열경화성 수지 및 열가소성 수지 중 하나 이상을 포함하며, 상기 열경화성 수지는 에폭시 수지, 페놀 수지, 비닐에스테르 수지, 불포화 폴리에스테르 수지 중 하나 이상을 포함하고, 상기 열가소성 수지는 폴리올레핀, 폴리아미드, 폴리에스테르, 폴리페닐렌에테르, 폴리아세탈, 폴리카르보네이트, 폴리페닐렌술피드, 폴리이미드, 폴리에테르이미드, 폴리에테르술폰 및 폴리케톤 중 하나 이상 포함할 수 있다.In one embodiment, the resin matrix comprises at least one of a thermosetting resin and a thermoplastic resin, and the thermosetting resin includes at least one of an epoxy resin, a phenol resin, a vinyl ester resin, and an unsaturated polyester resin, , Polyamide, polyester, polyphenylene ether, polyacetal, polycarbonate, polyphenylene sulfide, polyimide, polyetherimide, polyether sulfone and polyketone.

한 구체예에서 상기 단섬유 매트층의 두께는 0.1~50mm 이고, 섬유면중량(FAW)은 150~600g/m2이며, 상기 제1 연속섬유층 및 제2 연속섬유층의 두께는 각각 0.1~30mm이며, 섬유면중량(Fiber Aerial Weight, FAW)은 각각 150~600g/m2일 수 있다. 상기 범위에서 본 발명의 경량성이 우수하면서, 강성이 동시에 우수할 수 있다.In one embodiment, the thickness of the short fiber mat layer is 0.1 to 50 mm, the fiber surface weight (FAW) is 150 to 600 g / m 2 , the thicknesses of the first continuous fiber layer and the second continuous fiber layer are 0.1 to 30 mm , And fiber weight (FAW) may be 150 to 600 g / m 2 , respectively. In the above range, the light weight of the present invention is excellent, and the rigidity can be simultaneously excellent.

한 구체예에서, 상기 단섬유 매트층을 이루는 탄소 단섬유와, 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 필라멘트 수가 3K 내지 48K일 수 있다.In one embodiment, the short carbon fibers constituting the short fiber mat layer and the continuous carbon fibers constituting the first continuous fiber layer and the second continuous fiber layer may have a filament number of 3K to 48K.

한 구체예에서 상기 복합 성형체의 인장강도는 300MPa 이상일 수 있다. 상기 범위에서 자동차 외판용 부재로 사용하기 적합할 수 있다. 예를 들면, 상기 인장강도가 300~500 MPa일 수 있다.In one embodiment, the tensile strength of the composite formed article may be 300 MPa or more. And may be suitable for use as an automotive shell member in the above range. For example, the tensile strength may be 300 to 500 MPa.

한편, 상기 탄소섬유 강화 플라스틱을 이용한 자동차 외판재용 부재의 경우, 요구되는 물성이 내판 구조용 부재에 비하여 낮아, 고가의 연속섬유를 이용한 직조물이 사용되기에는 비효율적이며, 상대적으로 저가인 단섬유의 탄소섬유 강화 플라스틱 매트(mat)는, 외관성이 낮아 외판재용 부재로 사용되기에 부적합한 문제점이 있었다.On the other hand, in the case of a member for an automobile outer panel member using the carbon fiber-reinforced plastic, since the required physical properties are lower than those of the inner panel member, it is inefficient for using a woven material using expensive continuous fibers, The reinforced plastic mat (mat) has a problem in that it is not suitable for use as a member for a side plate member because of low appearance.

그러나 본 발명에 따른 재생 탄소섬유를 이용한 복합 성형체는, 재생 탄소섬유를 이용한 단섬유 매트층과, 연속 탄소섬유로 이루어진 연속섬유층을 적용하여, 기계적 강도 및 경량성이 동시에 우수하고, 재활용 소재를 사용하여 생산 비용이 저렴하여 경제성이 우수하며, 표면에 고유의 직조 패턴을 구현하여, 외관성 및 심미성이 우수하여 특히 자동차 루프(roof) 등 외판재용 부재로 사용하기 적합할 수 있다.However, the composite formed article using the regenerated carbon fiber according to the present invention is excellent in mechanical strength and light weight at the same time by applying a continuous fiber layer composed of continuous carbon fiber and a short fiber mat layer using regenerated carbon fiber, and using recycled materials And it is excellent in economical efficiency due to low production cost and has a unique woven pattern on the surface. Therefore, it is excellent in appearance and aesthetics, and can be particularly suitable for use as a member for outer panel material such as automobile roof.

이하, 본 발명의 바람직한 실시예를 통해 본 발명의 구성 및 작용을 더욱 상세히 설명하기로 한다. 다만, 이는 본 발명의 바람직한 예시로 제시된 것이며 어떠한 의미로도 이에 의해 본 발명이 제한되는 것으로 해석될 수는 없다.Hereinafter, the configuration and operation of the present invention will be described in more detail with reference to preferred embodiments of the present invention. It is to be understood, however, that the same is by way of illustration and example only and is not to be construed in a limiting sense.

실시예Example 및  And 비교예Comparative Example

실시예Example

단섬유 매트층, 상기 단섬유 매트층의 일면에 형성된 제1 연속섬유층 및 상기 단섬유 매트층의 타면에 형성된 제2 연속섬유층을 포함하는 복합섬유층; 및 상기 복합섬유층에 수지 매트릭스(에폭시 수지);를 함침하여 경화시켜 복합성형체를 준비하였다.A composite fiber layer comprising a short fiber mat, a first continuous fiber layer formed on one side of the short fiber mat layer, and a second continuous fiber layer formed on the other side of the short fiber mat; And the composite fiber layer was impregnated with a resin matrix (epoxy resin) and cured to prepare a composite molded body.

한 구체예에서 상기 단섬유 매트층은, 최대 길이가 2mm 이하이고, 섬유면중량(FAW)이 245g/m2인 재생 탄소섬유를 사용하였으며, 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는, 섬유면중량(Fiber Aerial Weight, FAW)이 각각 314g/m2 이고, 섬유 배향이 0°/90°를 가지며, 필라멘트 수: 12K 인 평직(plain woven)형태의 것을 사용하였다.One fiber mat layer wherein in embodiments is, and a maximum length of 2mm or less, the fiber face weight (FAW) is 245g / m 2, the play was used as the carbon fiber, wherein said first continuous fiber layer and the continuous form a second continuous fiber layer The carbon fibers used were plain woven fibers having a fiber aerial weight (FAW) of 314 g / m 2 , a fiber orientation of 0 ° / 90 °, and a filament count of 12K.

비교예Comparative Example

상기 단섬유 매트층을 적용하지 않은 것을 제외하고, 상기 실시예와 동일한 방법으로 성형체를 준비하였다.A molded article was prepared in the same manner as in the above example, except that the short-fiber mat layer was not applied.

상기 실시예 및 비교예 성형체 시편에 대하여, 인장강도 및 동일 부피의 중량을 측정하여 그 결과를 하기 표 1에 나타내었다.The tensile strength and the weight of the same volume were measured for the molded body specimens of the Examples and Comparative Examples, and the results are shown in Table 1 below.

구분division 인장강도(MPa)Tensile Strength (MPa) 중량(g)Weight (g) 실시예Example 340340 192192 비교예Comparative Example 500500 353353

상기 표 1의 결과를 참조하면, 본 발명의 실시예의 복합성형체는, 인장강도가 비교예 보다 낮으나, 중량이 비교예의 약 50% 수준으로, 경량성을 확보하면서도, 차량 외판재에 적합한 강성을 확보할 수 있음을 알 수 있었다. Referring to the results shown in Table 1, the composite molded article of the present invention has a tensile strength lower than that of the comparative example, but a weight of about 50% of that of the comparative example. I can see that it can be done.

도 2(a)는 본 발명에 따른 실시예 시편의 표면을 나타낸 것이며, 도 2(b)는 본 발명에 대한 비교예 시편의 표면을 나타낸 사진이며, 도 3(a)는 본 발명에 따른 실시예 복합성형체를 나타낸 것이며, 도 3(b)는 본 발명에 대한 비교예 성형체를 나타낸 사진이다. 상기 도 2 및 도 3을 참조하면, 본 발명에 따른 복합성형체는, 표면에 고유한 탄소섬유 직조 패턴이 드러나, 외관성이 우수함을 알 수 있었다.2 (b) is a photograph showing the surface of a specimen of a comparative example according to the present invention, and Fig. 3 (a) is a view showing the surface of the specimen according to the present invention Fig. 3 (b) is a photograph showing a molded article of a comparative example according to the present invention. Fig. Referring to FIGS. 2 and 3, it can be seen that the carbon fiber weave pattern inherent to the surface of the composite molded article according to the present invention is revealed and excellent in appearance.

본 발명의 단순한 변형 내지 변경은 이 분야의 통상의 지식을 가진 자에 의하여 용이하게 실시될 수 있으며, 이러한 변형이나 변경은 모두 본 발명의 영역에 포함되는 것으로 볼 수 있다.It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

10: 복합 섬유층 12: 단섬유 매트층
14: 제1 연속섬유층 16: 제2 연속섬유층
100: 복합 성형체10: Composite fiber layer 12: Short fiber mat layer
14: first continuous fibrous layer 16: second continuous fibrous layer
100: Composite formed body

Claims (7)

복합섬유층; 및
상기 복합섬유층에 함침된 수지 매트릭스;를 포함하며,
상기 복합섬유층은 단섬유 매트층, 상기 단섬유 매트층의 일면에 형성된 제1 연속섬유층 및 상기 단섬유 매트층의 타면에 형성된 제2 연속섬유층을 포함하는 복합 성형체이며,
상기 단섬유 매트층을 이루는 탄소 단섬유는 재생 탄소섬유를 포함하며, 상기 단섬유 매트층의 두께는 0.1~50mm 이고, 섬유면중량(FAW)은 150~600g/m2이며,
상기 제1 연속섬유층 및 제2 연속섬유층의 두께는 각각 0.1~30mm이며, 섬유면중량(FAW)은 각각 150~600g/m2 이고,
상기 복합 성형체의 인장강도는 300~500MPa인 것을 특징으로 하는 재생 탄소섬유를 이용한 자동차 외판용 복합 성형체.
Composite fiber layer; And
And a resin matrix impregnated in the composite fiber layer,
Wherein the composite fiber layer is a composite formed body including a short fiber mat, a first continuous fiber layer formed on one surface of the short fiber mat layer, and a second continuous fiber layer formed on the other surface of the short fiber mat layer,
The short carbon fibers constituting the short fiber mat layer include regenerated carbon fibers, the thickness of the short fiber mat layer is 0.1 to 50 mm, the fiber surface weight (FAW) is 150 to 600 g / m 2 ,
Said first continuous fiber layer and a second thickness of the continuous fiber layer is 0.1 ~ 30mm, respectively, the fiber surface is weight (FAW) and each of 150 ~ 600g / m 2,
Wherein the composite molded body has a tensile strength of 300 to 500 MPa.
삭제delete 제1항에 있어서,
상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 각각 능직, 평직, 주자직 또는 비크립핑 직물 형태인 것을 특징으로 하는 재생 탄소섬유를 이용한 자동차 외판용 복합 성형체.
The method according to claim 1,
Wherein the continuous carbon fibers constituting the first continuous fibrous layer and the second continuous fibrous layer are in the form of twill, plain weave, main weave or non creep weave, respectively.
제1항에 있어서,
상기 수지 매트릭스는 열경화성 수지 및 열가소성 수지 중 하나 이상을 포함하며,
상기 열경화성 수지는 에폭시 수지, 페놀 수지, 비닐에스테르 수지, 불포화 폴리에스테르 수지 중 하나 이상을 포함하고,
상기 열가소성 수지는 폴리올레핀, 폴리아미드, 폴리에스테르, 폴리페닐렌에테르, 폴리아세탈, 폴리카르보네이트, 폴리페닐렌술피드, 폴리이미드, 폴리에테르이미드, 폴리에테르술폰 및 폴리케톤 중 하나 이상 포함하는 것을 특징으로 하는 재생 탄소섬유를 이용한 자동차 외판용 복합 성형체.
The method according to claim 1,
Wherein the resin matrix comprises at least one of a thermosetting resin and a thermoplastic resin,
Wherein the thermosetting resin comprises at least one of an epoxy resin, a phenol resin, a vinyl ester resin, and an unsaturated polyester resin,
The thermoplastic resin is characterized by comprising at least one of polyolefin, polyamide, polyester, polyphenylene ether, polyacetal, polycarbonate, polyphenylene sulfide, polyimide, polyetherimide, polyether sulfone and polyketone A composite formed article for automotive exterior panels using recycled carbon fibers.
삭제delete 제1항에 있어서,
상기 단섬유 매트층을 이루는 탄소 단섬유와, 상기 제1 연속섬유층 및 제2 연속섬유층을 이루는 연속 탄소 섬유는 필라멘트 수가 각각 3K~48K인 것을 특징으로 하는 재생 탄소섬유를 이용한 자동차 외판용 복합 성형체.

The method according to claim 1,
Wherein the short carbon fibers constituting the short fiber mat layer and the continuous carbon fibers constituting the first continuous fiber layer and the second continuous fiber layer have a filament count of 3K to 48K, respectively.

삭제delete
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JP2008081872A (en) * 2006-09-27 2008-04-10 Takayasu Co Ltd Carbon fiber nonwoven fabric and method for producing the same
JP2012193466A (en) 2011-03-16 2012-10-11 Doshisha Nonwoven fabric, method for producing the nonwoven fabric, and sandwiched material including the nonwoven fabric
JP2013023184A (en) * 2011-07-26 2013-02-04 Toyota Industries Corp Outer panel for transportation apparatus and method of manufacturing the same

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Publication number Priority date Publication date Assignee Title
JP2008081872A (en) * 2006-09-27 2008-04-10 Takayasu Co Ltd Carbon fiber nonwoven fabric and method for producing the same
JP2012193466A (en) 2011-03-16 2012-10-11 Doshisha Nonwoven fabric, method for producing the nonwoven fabric, and sandwiched material including the nonwoven fabric
JP2013023184A (en) * 2011-07-26 2013-02-04 Toyota Industries Corp Outer panel for transportation apparatus and method of manufacturing the same

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KR20210078823A (en) 2019-12-19 2021-06-29 한국신발피혁연구원 Rubber composition for shoes outsole having recycled carbon fiber

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