KR102448814B1 - Method for manufacturing carbon-carbon composite preform - Google Patents
Method for manufacturing carbon-carbon composite preform Download PDFInfo
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- KR102448814B1 KR102448814B1 KR1020200124565A KR20200124565A KR102448814B1 KR 102448814 B1 KR102448814 B1 KR 102448814B1 KR 1020200124565 A KR1020200124565 A KR 1020200124565A KR 20200124565 A KR20200124565 A KR 20200124565A KR 102448814 B1 KR102448814 B1 KR 102448814B1
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- 239000002131 composite material Substances 0.000 title claims abstract description 36
- 238000000034 method Methods 0.000 title claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 title description 2
- 239000011203 carbon fibre reinforced carbon Substances 0.000 title description 2
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 205
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 179
- 239000004917 carbon fiber Substances 0.000 claims abstract description 126
- 239000000835 fiber Substances 0.000 claims abstract description 71
- 238000009958 sewing Methods 0.000 claims abstract description 71
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 38
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 38
- 229920005594 polymer fiber Polymers 0.000 claims description 39
- 239000003795 chemical substances by application Substances 0.000 claims description 12
- 238000004513 sizing Methods 0.000 claims description 12
- 238000010030 laminating Methods 0.000 abstract description 6
- 238000004080 punching Methods 0.000 abstract description 4
- 239000011347 resin Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 4
- 239000010410 layer Substances 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 2
- -1 Polyethylene Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 2
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000011229 interlayer Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 150000001721 carbon Chemical class 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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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
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
- B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
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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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
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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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
- B32B5/073—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper characterised by the fibrous or filamentary layer being mechanically connected to another layer by sewing, stitching, hook-and-loop fastening or stitchbonding
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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
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- 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
- B32B5/262—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 characterised by one fibrous or filamentary layer being a woven fabric layer
- B32B5/263—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 characterised by one fibrous or filamentary layer being a woven fabric layer next to one or more woven fabric layers
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- 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
- C04B35/522—Graphite
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/5208—Fibers
- C04B2235/5216—Inorganic
- C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
- C04B2235/5248—Carbon, e.g. graphite
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- 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
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
- C04B2235/5208—Fibers
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Abstract
본 발명은 탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성한 후 탄소직물 적층체를 바느질 섬유로 바느질하여 적층된 탄소직물 시트들을 서로 결속시켜 탄소복합재 프리폼을 제조한다. 따라서, 종래의 니들 펀칭 공법에서처럼 탄소섬유 웹을 구성하는 짧은 탄소섬유를 단지 수직방향으로 배열하여 탄소직물 시트들을 층간 결합시키는 것이 아닌, 적층된 탄소직물 시트들을 바느질에 의해 바느질 실로 묶어주므로, 탄소직물 시트 간 결속력이 강화된다. 이로 인해, 탄소복합재 프리폼의 내구성이 향상되고, 결국 탄소복합재 품질 향상으로 이어진다.The present invention prepares a carbon composite preform by laminating a plurality of carbon fabric sheets to form a carbon fabric laminate, then stitching the carbon fabric laminate with sewing fibers to bind the stacked carbon fabric sheets to each other. Therefore, instead of simply arranging the short carbon fibers constituting the carbon fiber web in a vertical direction as in the conventional needle punching method and bonding the carbon fabric sheets between layers, the stacked carbon fabric sheets are tied with a sewing thread by sewing, so the carbon fabric The bond between the sheets is strengthened. For this reason, the durability of the carbon composite preform is improved, which leads to improvement in the quality of the carbon composite material.
Description
본 발명은 탄소복합재 프리폼 제조방법에 관한 것이다.The present invention relates to a method for manufacturing a carbon composite preform.
탄소복합재(Carbon-Carbon Composite)는 경량이며, 고온에서 우수한 기계적 강도를 유지하며, 열·화학적 침식 환경에서 우수한 내식성, 내열성을 가지며, 우수한 마찰·마모 특성을 가진다.Carbon-Carbon Composite is lightweight, maintains excellent mechanical strength at high temperatures, has excellent corrosion resistance and heat resistance in thermal and chemical erosion environments, and has excellent friction and abrasion characteristics.
이러한 특성으로 인해, 탄소복합재는 항공기와 육상용 운송수단의 브레이크 디스크, 로켓 노즐, 고온 내열 지그 등에 사용된다.Due to these characteristics, carbon composites are used in brake discs, rocket nozzles, and high-temperature heat-resistant jigs of aircraft and land vehicles.
탄소복합재의 제조방법은 탄소복합재 프리폼(Preform)을 제조하는 공정과, 탄소복합재 프리폼을 밀도화하는 공정으로 크게 나눌 수 있다.The carbon composite material manufacturing method can be roughly divided into a process of manufacturing a carbon composite material preform and a process of densifying the carbon composite material preform.
탄소복합재 프리폼은 서로 적층된 탄소직물 시트들과 그 사이사이에 삽입된 탄소섬유 웹이 적층되고, 적층방향(수직방향)으로 니들펀칭(Needle Punching)되어 만들어진다.The carbon composite preform is made by stacking carbon fabric sheets stacked on top of each other and a carbon fiber web inserted therebetween, and needle punching in the stacking direction (vertical direction).
니들펀칭시, 미늘(Barb)들이 형성되어 있는 니들(needle)들이 탄소섬유 웹을 구성하는 짧은 탄소섬유를 적층방향(수직방향)으로 끌고 내려가, 탄소직물 시트들을 층간 결합시킨다.During needle punching, needles with barbs are formed to drag the short carbon fibers constituting the carbon fiber web in the lamination direction (vertical direction), thereby bonding the carbon fabric sheets between layers.
그러나, 탄소섬유 웹을 구성하는 짧은 탄소섬유가 수직방향으로 배열되어, 탄소직물 시트들을 층간 결합시킨 것만으로는, 탄소직물 시트들의 층간 결합력이 충분치 못하다.However, only short carbon fibers constituting the carbon fiber web are arranged in a vertical direction and the carbon fabric sheets are interlayer bonded, but the interlayer bonding force of the carbon fabric sheets is not sufficient.
또한, 미늘들이 형성되어 있는 니들들이 탄소직물 시트들을 반복적으로 관통하면서, 탄소직물 시트를 손상시킨다.In addition, the needles on which the barbs are formed repeatedly penetrate the carbon fabric sheets, thereby damaging the carbon fabric sheets.
이로 인해, 탄소복합재 프리폼의 내구성이 떨어지고, 결국 탄소복합재의 품질 저하로 이어진다.For this reason, the durability of the carbon composite preform is deteriorated, which leads to deterioration of the quality of the carbon composite material.
본 발명의 목적은, 상술한 문제점을 해결할 수 있는 탄소복합재 프리폼 제조방법을 제공하는 데 있다.An object of the present invention is to provide a method for manufacturing a carbon composite preform capable of solving the above-described problems.
상기 목적을 달성하기 위한 탄소복합재 프리폼 제조방법은, A carbon composite preform manufacturing method for achieving the above object,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계; 및A first step of stacking a plurality of carbon fabric sheets to form a carbon fabric laminate; and
상기 탄소직물 적층체를 일방향 탄소섬유로 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계를 포함하는 것을 특징으로 한다.and a second step of binding the laminated carbon fabric sheets to each other by sewing the carbon fabric laminate with sewing fibers made of unidirectional carbon fibers.
또한, 상기 목적을 달성하기 위한 탄소복합재 프리폼 제조방법은, In addition, the carbon composite material preform manufacturing method for achieving the above object,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계; 및A first step of stacking a plurality of carbon fabric sheets to form a carbon fabric laminate; and
상기 탄소직물 적층체를 꼬인 탄소섬유로 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계를 포함하는 것을 특징으로 한다.and a second step of binding the laminated carbon fabric sheets to each other by sewing the carbon fabric laminate with sewing fibers made of twisted carbon fibers.
또한, 상기 목적을 달성하기 위한 탄소복합재 프리폼 제조방법은, In addition, the carbon composite material preform manufacturing method for achieving the above object,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계; 및A first step of stacking a plurality of carbon fabric sheets to form a carbon fabric laminate; and
상기 탄소직물 적층체를 꼬인 또는 꼬이지 않은 탄소섬유의 외면을 고분자 섬유로 감싸서 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계를 포함하는 것을 특징으로 한다.and a second step of binding the laminated carbon fabric sheets to each other by sewing the carbon fabric laminate with a sewing fiber made by wrapping the outer surface of the twisted or untwisted carbon fiber with a polymer fiber.
본 발명은 탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성한 후 탄소직물 적층체를 바느질 섬유로 바느질하여 적층된 탄소직물 시트들을 서로 결속시켜 탄소복합재 프리폼을 제조한다. 따라서, 종래의 니들 펀칭 공법에서처럼 탄소섬유 웹을 구성하는 짧은 탄소섬유를 단지 수직방향으로 배열하여 탄소직물 시트들을 층간 결합시키는 것이 아닌, 적층된 탄소직물 시트들을 바느질에 의해 바느질 실로 묶어주므로, 탄소직물 시트 간 결속력이 강화된다. 이로 인해, 탄소복합재 프리폼의 내구성이 향상되고, 결국 탄소복합재 품질 향상으로 이어진다. The present invention prepares a carbon composite preform by laminating a plurality of carbon fabric sheets to form a carbon fabric laminate, then stitching the carbon fabric laminate with sewing fibers to bind the stacked carbon fabric sheets to each other. Therefore, instead of simply arranging the short carbon fibers constituting the carbon fiber web in a vertical direction as in the conventional needle punching method and bonding the carbon fabric sheets between layers, the stacked carbon fabric sheets are tied with a sewing thread by sewing, so the carbon fabric The bond between the sheets is strengthened. For this reason, the durability of the carbon composite preform is improved, which leads to improvement in the quality of the carbon composite material.
본 발명은 탄소섬유를 바느질 하여 탄소직물 시트들을 층간 결합시키므로, 미늘(barb)들이 형성되어 있는 니들들을 탄소직물 시트들을 반복적으로 관통시킬 필요가 없어, 탄소직물 시트의 손상이 줄어든다.Since the present invention stitches carbon fibers to bond the carbon fabric sheets between layers, there is no need to repeatedly pierce the carbon fabric sheets with needles having barbs formed therein, thereby reducing damage to the carbon fabric sheets.
본 발명은 판재형 뿐만 아니라, U-Shape, I-Shape 형태 등 다양한 형태의 탄소복합재 프리폼을, 탄소직물 시트를 바느질로 하여 만들 수 있다.According to the present invention, carbon composite preforms of various types such as U-Shape, I-Shape, etc., as well as plate type, can be made by sewing carbon fabric sheets.
본 발명은 꼬인 탄소섬유를 바느질 섬유로 사용하여, 바느질 섬유가 탄소직물 시트를 관통하면서 발생하는 마찰력을 꼬인 방향으로 분산시킨다. 이로 인해, 표면 마찰에 약한 탄소섬유로 구성된 바느질 섬유가 손상되는 것을 줄일 수 있다. 또한, 탄소섬유에 꼬임을 줌으로 인해 바느질 섬유의 강도가 보강된다.The present invention uses twisted carbon fibers as sewing fibers to disperse frictional force generated while the sewing fibers penetrate the carbon fabric sheet in the twisted direction. Due to this, it is possible to reduce the damage to the sewing fibers composed of carbon fibers weak to surface friction. In addition, by giving twist to the carbon fiber, the strength of the sewing fiber is reinforced.
본 발명은 꼬인 탄소섬유를 고분자 섬유로 감싼 바느질 섬유를 사용하여, 바느질 섬유가 탄소직물 시트를 관통할 때, 탄소섬유가 직접적으로 탄소직물 시트와 마찰되는 것을 막는다. 이로 인해, 표면 마찰에 약한 탄소섬유로 구성된 바느질 섬유가 손상되는 것을 막을 수 있다. 또한, 고분자 섬유로 인해, 바느질 섬유의 강도가 더 보강된다.The present invention prevents the carbon fiber from directly rubbing with the carbon fabric sheet when the sewing fiber penetrates the carbon fabric sheet by using a sewing fiber wrapped with a polymer fiber in a twisted carbon fiber. Due to this, it is possible to prevent damage to the sewing fibers composed of carbon fibers that are weak in surface friction. Also, due to the polymer fiber, the strength of the sewing fiber is further reinforced.
도 1은 본 발명의 제1실시예에 따른 탄소복합재 프리폼 제조방법을 나타낸 순서도이다.
도 2는 본 발명의 제1실시예에 따른 탄소복합재 프리폼 제조방법을 설명하기 위한 모식도이다.
도 3은 도 2에 도시된 탄소복합재 프리폼의 A-A선에 따른 단면을 나타낸 도면이다.
도 4는 바느질 섬유를 나타낸 것으로, (a)는 일방향 탄소섬유로 이루어진 바느질 섬유 (b)는 꼬인 탄소섬유로 이루어진 바느질 섬유 (c)는 꼬인 탄소섬유의 외면을 고분자 섬유로 감싸서 이루어진 바느질 섬유 (d)는 일방향 탄소섬유의 외면을 고분자 섬유로 감싸서 이루어진 바느질 섬유를 나타낸 도면이다.
도 5는 본 발명의 제2실시예에 따른 탄소복합재 프리폼 제조방법을 나타낸 순서도이다.
도 6은 본 발명의 제3실시예에 따른 탄소복합재 프리폼 제조방법을 나타낸 순서도이다.1 is a flowchart showing a carbon composite preform manufacturing method according to a first embodiment of the present invention.
2 is a schematic diagram for explaining a carbon composite preform manufacturing method according to the first embodiment of the present invention.
FIG. 3 is a view showing a cross-section taken along line AA of the carbon composite preform shown in FIG. 2 .
Figure 4 shows a sewing fiber, (a) is a sewing fiber made of unidirectional carbon fiber (b) is a sewing fiber made of twisted carbon fiber (c) is a sewing fiber made by wrapping the outer surface of the twisted carbon fiber with a polymer fiber (d) ) is a diagram showing a sewing fiber made by wrapping the outer surface of a unidirectional carbon fiber with a polymer fiber.
5 is a flowchart illustrating a method for manufacturing a carbon composite preform according to a second embodiment of the present invention.
6 is a flowchart illustrating a method for manufacturing a carbon composite preform according to a third embodiment of the present invention.
이하, 본 발명의 제1실시예에 따른 탄소복합재 프리폼 제조방법을 자세히 설명한다.Hereinafter, a method for manufacturing a carbon composite preform according to a first embodiment of the present invention will be described in detail.
도 1에 도시된 바와 같이, 본 발명의 일 실시예에 따른 탄소복합재 프리폼 제조방법은, As shown in Figure 1, the carbon composite preform manufacturing method according to an embodiment of the present invention,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계(S11); 및A first step of forming a carbon fabric laminate by laminating a plurality of carbon fabric sheets (S11); and
상기 탄소직물 적층체를 일방향 탄소섬유로 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계(S12)로 구성된다. It consists of a second step (S12) of binding the carbon fabric sheets stacked by sewing the carbon fabric laminate with a sewing fiber made of one-way carbon fiber to each other.
이하, 제1단계(S11)를 설명한다.Hereinafter, the first step (S11) will be described.
도 2에 도시된 바와 같이, 탄소직물 시트(110)를 복수 개 적층하여 탄소직물 적층체(100)를 형성한다.As shown in FIG. 2 , a plurality of
이를 위해, 먼저 탄소직물 시트(110)를 준비한다.To this end, first, the
탄소직물 시트(110)는 다양한 형태가 있다.
탄소직물 시트(110)의 일예로, 탄소섬유들이 길이방향으로 평행하게 배열된 후 횡방향으로 묶인 시트가 있다. 탄소섬유들을 횡방향으로 묶어주는 실로, 폴리카보네이트(polycarbonate), ABS수지(Acrylonitrile Butadiene Styrene copolymer), 스티렌 수지(Styrene resin), 폴리에틸렌(Polyethylene), 아크릴 수지(Acrylic resin), 폴리비닐알코올(Polyvinylalcohol) 등으로 만들어진 실이 있다.As an example of the
탄소직물 시트(110)의 다른 예로, 탄소섬유가 평직, 능직, 주자직으로 직조된 시트가 있다.As another example of the
상술한 탄소직물 시트(110)는 수지(resin)가 포함된 드라이 시트(dry fabric) 형태를 가지거나, 수지(resin)가 포함된 프리프레그(prepreg) 형태를 가질 수 있다.The above-described
다음으로, 탄소직물 시트(110)를 적층한다.Next, the
탄소직물 시트(110)가 일방향 탄소섬유로 구성된 경우, 탄소직물 시트(110)들을 일방향 탄소섬유의 길이 방향이 일치하도록 동일한 방향으로 적층할 수 있다. 또는, 탄소직물 시트(110)들을 일방향 탄소섬유의 길이 방향이 서로 다르게 적층할 수 있다. 예컨대, 일방향 탄소섬유의 길이방향이 0도와 90도로 교차되게 적층하거나, 일방향 탄소섬유의 길이방향이 -90도~90도 사이의 각도로 서로 엇갈리게 적층될 수도 있다.When the
한편, 탄소직물 시트(110)가 직조된 시트인 경우, 평직이면 평직끼리, 능직이면 능직끼리, 주자직이 주자직끼리, 동일한 방식으로 직조된 탄소직물 시트(110)들을 적층할 수 있다. 또는, 탄소직물 시트(110)가 직조된 시트인 경우, 서로 다른 방식(평직, 능직, 주자직)으로 직조된 탄소직물 시트(110)들을 섞어 적층할 수 있다.On the other hand, if the
상술한 적층 방식으로 탄소복합프리폼의 기계적 물성을 조절한다.The mechanical properties of the carbon composite preform are controlled by the above-described lamination method.
이하, 제2단계(S12)를 설명한다.Hereinafter, the second step (S12) will be described.
도 2 및 도 3에 도시된 바와 같이, 탄소직물 시트(110)를 복수 개 적층하여 형성된 탄소직물 적층체(100)를 일방향 탄소섬유로 이루어진 바느질 섬유(200, 210)로 바느질하여(Sewing) 적층된 탄소직물 시트(110)들을 서로 결속시킨다.2 and 3, the
바느질은 바느질 섬유(200, 210)가 탄소직물 적층체(100)의 상면에서 하면 또는 하면에서 상면으로 두께 방향으로 관통하도록 이루어지며, 바느질 섬유(200, 210)에 의해 탄소직물 적층체(100)를 구성하는 복수 개의 탄소직물 시트(110)들이 두께 방향으로 서로 결속되어 고정된다. 바느질은 일정 간격의 바늘땀을 유지하도록 이루어지며 탄소직물 적층체(100)에 구김이나 주름이 가지 않도록 바느질 섬유(200, 210)에 설정된 장력이 일정하게 유지되도록 이루어진다. Sewing is made so that the
도 4(a)에 도시된 바와 같이, 바느질 섬유(200, 210)는 일방향 탄소섬유(CF)로 이루어진다. 즉, 바느질 섬유(200, 210)는 탄소섬유(CF)들이 길이방향으로 평행하게 배열된 형태로, 탄소섬유(CF)들이 꼬임 없이 가지런히 배열된 상태를 가진다. As shown in Fig. 4(a), the
바느질 섬유(200, 210)를 구성하는 탄소섬유(CF)는 일정 길이로 절단된 섬유(Stretched Broken Fiber)이거나 연속 섬유(Continuous Fiber)일 수 있다. Carbon fiber (CF) constituting the
탄소섬유(CF)는 사이징제에 의해 서로 결속되어 있다. 이로 인해, 탄소섬유(CF)는 흩어지지 않고, 섬유의 배향 흐트러짐이 억제된다. 또한, 탄소섬유(CF)의 표면에 코팅된 사이징제에 의해, 탄소섬유(CF)가 보호된다.Carbon fibers (CF) are bound to each other by a sizing agent. For this reason, the carbon fiber (CF) does not scatter, and the disorder of the orientation of a fiber is suppressed. In addition, the carbon fiber (CF) is protected by the sizing agent coated on the surface of the carbon fiber (CF).
탄소섬유(CF)는 1k ~ 6k의 탄소 필라멘트로 구성되는 것이 바람직하다. 탄소섬유(CF)가 두꺼울수록 바느질이 어렵기 때문이다.The carbon fiber (CF) is preferably composed of 1k to 6k carbon filaments. This is because the thicker the carbon fiber (CF), the more difficult it is to sew.
이하, 본 발명의 제2실시예에 따른 탄소복합재 프리폼 제조방법을 자세히 설명한다. 도 2 및 도 3을 기본적으로 참조한다. Hereinafter, a method for manufacturing a carbon composite preform according to a second embodiment of the present invention will be described in detail. Reference is made basically to Figures 2 and 3 .
도 5에 도시된 바와 같이, 본 발명의 제2실시예에 따른 탄소복합재 프리폼 제조방법은, As shown in Figure 5, the carbon composite preform manufacturing method according to the second embodiment of the present invention,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계(S21); 및A first step of forming a carbon fabric laminate by laminating a plurality of carbon fabric sheets (S21); and
상기 탄소직물 적층체를 꼬인 탄소섬유로 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계(S22)로 구성된다. It consists of a second step (S22) of binding the laminated carbon fabric sheets to each other by sewing the carbon fabric laminate with sewing fibers made of twisted carbon fibers.
본 실시예는 제1실시예와 비교하여 바느질 섬유에 차이가 있을 뿐 다른 부분은 동일하므로, 동일한 내용에 대해서는 그 설명을 생략한다. In this embodiment, there is a difference in the sewing fibers compared to the first embodiment, but other parts are the same. Therefore, the description of the same content will be omitted.
도 4(b)에 도시된 바와 같이, 바느질 섬유(200, 220)가 꼬인 탄소섬유(CF)로 이루어진다. 즉, 바느질 섬유(200, 220)는 길이방향으로 평행하게 배열된 일방향 탄소섬유(CF)에 꼬임을 준 형태이다. As shown in Fig. 4(b), the
바느질 섬유(200, 220)를 구성하는 탄소섬유(CF)는 일정 길이로 절단된 섬유(Stretched Broken Fiber)이거나 연속 섬유(Continuous Fiber)일 수 있다. Carbon fiber (CF) constituting the
탄소섬유(CF)는 사이징제에 의해 서로 결속되어 있다. 이로 인해, 탄소섬유(CF)는 흩어지지 않고, 섬유의 배향 흐트러짐이 억제된다. 또한, 탄소섬유(CF)의 표면에 코팅된 사이징제에 의해, 탄소섬유(CF)가 보호된다.Carbon fibers (CF) are bound to each other by a sizing agent. For this reason, the carbon fiber (CF) does not scatter, and the disorder of the orientation of a fiber is suppressed. In addition, the carbon fiber (CF) is protected by the sizing agent coated on the surface of the carbon fiber (CF).
탄소섬유(CF)는 1k ~ 6k의 탄소 필라멘트로 구성되는 것이 바람직하다. 탄소섬유(CF)가 두꺼울수록 바느질이 어렵기 때문이다.The carbon fiber (CF) is preferably composed of 1k to 6k carbon filaments. This is because the thicker the carbon fiber (CF), the more difficult it is to sew.
일방향 탄소섬유(CF)에 꼬임을 줌으로써 바느질 섬유(200, 220)가 탄소직물 시트(110)를 관통하면서 발생하는 마찰력을 꼬인 방향으로 분산시킨다. 이로 인해, 표면 마찰에 약한 탄소섬유로 구성된 바느질 섬유(200, 220)가 손상되는 것을 줄일 수 있다.By twisting the unidirectional carbon fiber (CF), the friction force generated while the
제2실시예를 사용하면, 사이징제가 바느질 섬유(200, 220)의 손상을 1차로 줄이고, 일방향 탄소섬유(CF)의 꼬임이 바느질 섬유(200, 220)의 손상을 2차로 줄일 수 있다.If the second embodiment is used, the sizing agent may primarily reduce the damage to the
이하, 본 발명의 제3실시예에 따른 탄소복합재 프리폼 제조방법을 자세히 설명한다. 도 2 및 도 3을 기본적으로 참조한다. Hereinafter, a method for manufacturing a carbon composite preform according to a third embodiment of the present invention will be described in detail. Reference is made basically to Figures 2 and 3 .
도 6에 도시된 바와 같이, 본 발명의 제3실시예에 따른 탄소복합재 프리폼 제조방법은, As shown in Figure 6, the carbon composite preform manufacturing method according to the third embodiment of the present invention,
탄소직물 시트를 복수 개 적층하여 탄소직물 적층체를 형성하는 제1단계(S31); 및A first step of forming a carbon fabric laminate by laminating a plurality of carbon fabric sheets (S31); and
상기 탄소직물 적층체를 꼬인 또는 꼬이지 않은 탄소섬유의 외면을 고분자 섬유로 감싸서 이루어진 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시키는 제2단계(S32)로 구성된다. It consists of a second step (S32) of binding the laminated carbon fabric sheets to each other by sewing the carbon fabric laminate with a sewing fiber made by wrapping the outer surface of the twisted or untwisted carbon fiber with a polymer fiber.
본 실시예는 제1실시예와 비교하여 바느질 섬유에 차이가 있을 뿐 다른 부분은 동일하므로, 동일한 내용에 대해서는 그 설명을 생략한다. In this embodiment, there is a difference in the sewing fibers compared to the first embodiment, but other parts are the same. Therefore, the description of the same content will be omitted.
도 4(c)에 도시된 바와 같이, 바느질 섬유(200, 230)는 꼬인 탄소섬유(CF)의 외면을 고분자 섬유(PF)로 감싸 이루어진다. 즉, 바느질 섬유(200, 230)는 길이방향으로 평행하게 배열된 일방향 탄소섬유(CF)에 꼬임을 준 후 그 외면에 고분자 섬유(PF)를 감싼 형태를 가진다.As shown in Fig. 4(c), the
또는, 도 4(d)에 도시된 바와 같이, 바느질 섬유(200, 240)는 꼬이지 않은 탄소섬유(CF)의 외면을 고분자 섬유(PF)로 감싸 이루어진다. 즉, 바느질 섬유(200, 240)는 길이방향으로 평행하게 배열된 일방향 탄소섬유(CF)에 꼬임을 주지 않고, 그대로 외면에 고분자 섬유(PF)를 감싼 형태를 가진다.Alternatively, as shown in Fig. 4(d), the
고분자 섬유(PF)는 한 가닥 이상이 사용될 수 있다. 고분자 섬유(PF)는 길이 방향으로 평행하게 배열된 일방향 섬유 형태이거나 일방향 섬유에 꼬임을 준 형태일 수 있다. One or more polymer fibers (PF) may be used. The polymer fibers (PF) may be in the form of unidirectional fibers arranged in parallel in the longitudinal direction or in the form of twisting the unidirectional fibers.
도 4(c)에 도시된 바느질 섬유(220, 230)를 구성하는 탄소섬유(CF) 또는 도 4(d)에 도시된 바느질 섬유(230, 240)를 구성하는 탄소섬유(CF)는 일정 길이로 절단된 섬유(Stretched Broken Fiber)이거나 연속 섬유(Continuous Fiber)일 수 있다. The carbon fiber (CF) constituting the
탄소섬유(CF)는 사이징제에 의해 서로 결속되어 있다. 이로 인해, 탄소섬유(CF)는 흩어지지 않고, 섬유의 배향 흐트러짐이 억제된다. 또한, 탄소섬유(CF)의 표면에 코팅된 사이징제에 의해, 탄소섬유(CF)가 보호된다.Carbon fibers (CF) are bound to each other by a sizing agent. For this reason, the carbon fiber (CF) does not scatter, and the disorder of the orientation of a fiber is suppressed. In addition, the carbon fiber (CF) is protected by the sizing agent coated on the surface of the carbon fiber (CF).
고분자 섬유(PF)는 탄소섬유(CF)의 표면에 코팅된 사이징제에 의해 탄소섬유(CF)에 접착되어, 탄소섬유(CF)를 감싼 형태를 유지한다.The polymer fiber (PF) is adhered to the carbon fiber (CF) by the sizing agent coated on the surface of the carbon fiber (CF), and maintains the shape surrounding the carbon fiber (CF).
탄소섬유(CF)는 1k ~ 6k의 탄소 필라멘트로 구성되는 것이 바람직하다. 탄소섬유(CF)가 두꺼울수록 바느질이 어렵기 때문이다.The carbon fiber (CF) is preferably composed of 1k to 6k carbon filaments. This is because the thicker the carbon fiber (CF), the more difficult it is to sew.
고분자 섬유(PF)로, 폴리카보네이트(polycarbonate), ABS수지(Acrylonitrile Butadiene Styrene copolymer), 스티렌 수지(Styrene resin), 폴리에틸렌(Polyethylene), 아크릴 수지(Acrylic resin), 폴리비닐알코올(Polyvinylalcohol) 등으로 만들어진 고분자 섬유가 있다.Polymer fiber (PF), made of polycarbonate, ABS resin (Acrylonitrile Butadiene Styrene copolymer), styrene resin, polyethylene, acrylic resin, polyvinylalcohol, etc. polymer fibers.
고분자 섬유(PF)를 사용함으로써, 도 4(c)에 도시된 바느질 섬유(200,230) 또는 도 4(d)에 도시된 바느질 섬유(200,240)가 탄소직물 시트를 관통할 때, 탄소섬유가 직접적으로 탄소직물 시트와 마찰되지 않아, 표면 마찰에 약한 탄소섬유로 구성된 바느질 섬유가 손상되는 것을 막을 수 있다. 또한, 고분자 섬유(PF)로 인해, 바느질 섬유의 강도가 보강된다.By using polymer fibers (PF), when the
한편, 고분자 섬유(PF)가 꼬인 형태로, 탄소섬유(CF)를 감싼 경우, 바느질 섬유가 탄소직물 시트를 관통하면서 발생하는 마찰력을 꼬인 방향으로 분산시켜, 고분자 섬유(PF)가 손상되는 것을 줄일 수 있다.On the other hand, when the polymer fiber (PF) is wrapped around the carbon fiber (CF) in a twisted form, the friction force generated while the sewing fiber penetrates the carbon fabric sheet is dispersed in the twisted direction to reduce damage to the polymer fiber (PF). can
제3실시예를 사용하면, 사이징제가 바느질 섬유의 손상을 1차로 줄이고, 탄소섬유(CF)를 감싼 고분자 섬유(PF)가 바느질 섬유의 손상을 2차로 줄일 수 있다. 여기에 탄소섬유(CF)에 꼬임까지 주면 바느질 섬유의 손상을 3차로 줄일 수 있다.Using the third embodiment, the sizing agent can primarily reduce the damage to the sewing fiber, and the polymer fiber (PF) wrapped around the carbon fiber (CF) can secondarily reduce the damage to the sewing fiber. Here, if the carbon fiber (CF) is twisted, the damage to the sewing fiber can be reduced to the third degree.
100: 탄소직물 적층체 110: 탄소직물 시트
200, 210, 220, 230: 바느질 섬유
CF: 탄소섬유 PF: 고분자 섬유100: carbon fabric laminate 110: carbon fabric sheet
200, 210, 220, 230: sewing fibers
CF: carbon fiber PF: polymer fiber
Claims (5)
상기 바느질 섬유는, 탄소섬유와, 상기 탄소섬유를 감싸는 고분자 섬유로 구성되며,
상기 탄소섬유는 꼬인 형태를 가지며, 사이징제에 의해 결속된 1k ~ 6k의 탄소 필라멘트로 구성되며,
상기 고분자 섬유는 꼬인 형태를 가지며, 상기 사이징제에 의해 상기 탄소섬유에 접착되어, 상기 탄소섬유를 감싼 형태를 유지하며,
상기 탄소직물 적층체를 상기 바느질 섬유로 바느질하여 적층된 상기 탄소직물 시트들을 서로 결속시킬 때,
상기 바느질 섬유의 손상을, 상기 사이징제가 1차로 줄이고, 상기 고분자 섬유가 2차로 줄이고, 상기 탄소섬유의 꼬인 형태 및 상기 고분자 섬유의 꼬인 형태가 3차로 줄이는 것을 특징으로 하는 탄소복합재 프리폼 제조방법.In a carbon composite preform manufacturing method in which a plurality of carbon fabric sheets are laminated to form a carbon fabric laminate, and the carbon fabric laminate is stitched with sewing fibers to bind the laminated carbon fabric sheets to each other,
The sewing fiber is composed of a carbon fiber and a polymer fiber surrounding the carbon fiber,
The carbon fiber has a twisted form and is composed of 1k to 6k carbon filaments bound by a sizing agent,
The polymer fiber has a twisted shape, is adhered to the carbon fiber by the sizing agent, and maintains a shape surrounding the carbon fiber,
When binding the carbon fabric sheets laminated by sewing the carbon fabric laminate with the sewing fiber to each other,
The carbon composite preform manufacturing method, characterized in that the sizing agent reduces the damage of the sewing fibers first, the polymer fiber reduces the second, and the twisted form of the carbon fiber and the twisted form of the polymer fiber reduces the third.
상기 탄소섬유는 일정 길이로 절단된 것을 특징으로 하는 탄소복합재 프리폼 제조방법.4. The method of claim 3,
The carbon fiber is a carbon composite preform manufacturing method, characterized in that cut to a predetermined length.
상기 탄소섬유는 연속적인 것을 특징으로 하는 탄소복합재 프리폼 제조방법.4. The method of claim 3,
The carbon fiber is a carbon composite preform manufacturing method, characterized in that the continuous.
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