US20140230634A1 - Reinforced fiber/resin fiber composite, and method for manufacturing same - Google Patents

Reinforced fiber/resin fiber composite, and method for manufacturing same Download PDF

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US20140230634A1
US20140230634A1 US14/346,401 US201214346401A US2014230634A1 US 20140230634 A1 US20140230634 A1 US 20140230634A1 US 201214346401 A US201214346401 A US 201214346401A US 2014230634 A1 US2014230634 A1 US 2014230634A1
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fiber
reinforced
thermoplastic resin
resin
long
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Asami Nakai
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Kyoto Institute of Technology NUC
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    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/02—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/047—Reinforcing macromolecular compounds with loose or coherent fibrous material with mixed fibrous material
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
    • D04C1/06—Braid or lace serving particular purposes
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2201/00—Ropes or cables
    • D07B2201/10—Rope or cable structures
    • D07B2201/1096—Rope or cable structures braided
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/024—Fabric incorporating additional compounds
    • D10B2403/0241—Fabric incorporating additional compounds enhancing mechanical properties
    • D10B2403/02411—Fabric incorporating additional compounds enhancing mechanical properties with a single array of unbent yarn, e.g. unidirectional reinforcement fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • the present invention relates to reinforced fiber/resin fiber composites which are an intermediate material for a long-fiber reinforced thermoplastic resin structure, and methods for manufacturing the same.
  • Fiber reinforced thermoplastic resins which are a combination of a thermoplastic resin and a fiber, have good properties, i.e., light weight and high strength, and therefore, are used in a variety of fields. For example, in transport machines, such as automobiles, ships, aircrafts, etc., molded products of fiber reinforced thermoplastic resins are used as a portion of parts to improve fuel efficiency and safety.
  • fiber reinforced thermoplastic resin As a type of fiber reinforced thermoplastic resin, fiber reinforced plastics (FRPs), which are a molded product of a thermoplastic resin to which a short fiber is added, have been well known.
  • FRPs fiber reinforced plastics
  • a long-fiber reinforced thermoplastic resin which is a combination of a thermoplastic resin and a long fiber (e.g., a reinforced fiber, such as a carbon fiber etc.)
  • long fiber refers to a fiber extending in the longitudinal direction (so-called a “fiber”).
  • the long-fiber reinforced thermoplastic resin has a number of advantages: (1) very good impact resistance; (2) good recyclability because it can be melted by heat; (3) the ability to be quickly molded because molding of it does not involve chemical reaction; (4) the ease of storage of an intermediate material (prepreg) before molding because chemical reaction has already been ended; (5) the ease of changing shape or attachment by being melted by heat; etc. Therefore, the long-fiber reinforced thermoplastic resin is expected as a very useful material in the future.
  • the thermoplastic resin has a very high melt viscosity, and therefore, it is disadvantageously difficult to impregnate the long fiber with the thermoplastic resin. As the impregnation characteristics of the resin decrease, the molded product cannot exhibit sufficient strength. Also, it is important for the long-fiber reinforced thermoplastic resin to improve interfacial characteristics between the long fiber and the thermoplastic resin. If the interfacial characteristics are insufficient, the long fiber and the thermoplastic resin are likely to come off the adhesion surface therebetween, so that the molded product is likely to be damaged.
  • the impregnation characteristics of the thermoplastic resin with respect to the long fiber become better, the interfacial characteristics between the long fiber and the thermoplastic resin become worse.
  • the contact angle of the thermoplastic resin with respect to the long fiber increases (i.e., the wettability of the long fiber surface deteriorates), and as a result, the impregnation characteristics become worse.
  • the impregnation characteristics become worse.
  • a long-fiber reinforced thermoplastic resin structure is manufactured using the long-fiber reinforced thermoplastic resin, it is desirable to simultaneously provide as good impregnation characteristics and interfacial characteristics as possible.
  • the term “intermediate material” refers to a composite or mixture of the long fiber and the thermoplastic resin.
  • a “carbon fiber reinforced thermoplastic resin tape” which is a tape-like molded product of a carbon fiber (long fiber) impregnated with a thermoplastic resin (see, for example, Patent Document 1).
  • Patent Document 1 opened carbon fiber strands are immersed in a melted thermoplastic resin bath to impregnate a carbon fiber with a thermoplastic resin, and then, the resin-impregnated carbon fiber is passed through a nozzle for molding, whereby a thin and long carbon fiber reinforced thermoplastic resin tape is formed.
  • the carbon fiber reinforced thermoplastic resin tape is wound around the surface of a target structure and is then cooled to solidify. As a result, the structure is reinforced.
  • a “commingled yarn for a composite material (composite material commingled yarn)” is known in which a continuous reinforced fiber bundle (long fiber) is commingled with a continuous thermoplastic resin fiber bundle (see, for example, Patent Document 2).
  • a non-twisted continuous reinforced fiber bundle and a non-twisted continuous thermoplastic resin fiber bundle are opened before being commingled together, to obtain a composite material commingled yarn.
  • the composite material commingled yarn is, for example, processed into woven or knitted fabric.
  • the carbon fiber reinforced thermoplastic resin tape of Patent Document 1 long fiber strands impregnated with a thermoplastic resin extend generally in parallel in the longitudinal direction. Therefore, the mixture ratio of the long fiber and the thermoplastic resin are generally uniform irrespective of the position of the tape.
  • the composition of the long-fiber reinforced thermoplastic resin structure as a final product cannot be accurately controlled in a position-dependent manner. It is also difficult to control the composition, and therefore, it may be difficult to simultaneously achieve good impregnation characteristics of the long fiber and good interfacial characteristics between the long fiber and the thermoplastic resin.
  • a structure to which the carbon fiber reinforced thermoplastic resin tape is applicable is limited to those having a flat surface or a simple curved surface.
  • the carbon fiber reinforced thermoplastic resin tape is likely to have excessive stiffness due to its structure and has poor tackiness. Therefore, it is not easy to handle the carbon fiber reinforced thermoplastic resin tape. Note that, in order to manufacture the carbon fiber reinforced thermoplastic resin tape, it is necessary to use dedicated equipment, such as a thermoplastic resin bath, a nozzle for molding, etc., leading to an increase in cost.
  • the continuous reinforced fiber bundle and the continuous thermoplastic resin fiber bundle are only simply commingled together, and therefore, it is difficult to accurately control the mixture ratio of both of the fibers along the longitudinal direction. Therefore, also in Patent Document 2, it is not possible to simultaneously achieve good impregnation characteristics of the long fiber and good interfacial characteristics between the long fiber and the thermoplastic resin. Also, the reinforced fiber is likely to be damaged due to friction during opening of the continuous reinforced fiber bundle or commingling of the continuous reinforced fiber bundle and the continuous thermoplastic resin fiber bundle. When the composite material commingled yarn is processed into woven or knitted fabric, each fiber is likely to be damaged. Moreover, when the composite material commingled yarn is manufactured, a portion of the fiber strands may be cut or come off, etc., to be lost during opening and commingling, resulting in a decrease in the yield of the final product.
  • a reinforced fiber/resin fiber composite has not yet been developed which is an optimum intermediate material including a reinforced fiber and a resin fiber for manufacture of a long-fiber reinforced thermoplastic resin structure.
  • the present invention has been made. It is an object of the present invention to provide a reinforced fiber/resin fiber composite (intermediate material) in which the ratio and arrangement of a long fiber and a thermoplastic resin fiber are accurately controlled in order to simultaneously achieve different physical properties (e.g., impregnation characteristics, interfacial characteristics, etc.) of the reinforced fiber and the resin fiber. It is another object of the present invention to provide a method for efficiently and reliably manufacturing such a reinforced fiber/resin fiber composite at low cost.
  • a reinforced fiber/resin fiber composite according to the present invention has the following characteristic features.
  • the reinforced fiber/resin fiber composite is a reinforced fiber/resin fiber composite which is an intermediate material for a long-fiber reinforced thermoplastic resin structure, in which
  • the reinforced fiber is a long fiber extending in a longitudinal direction
  • the resin fiber includes at least two thermoplastic resin fibers, and
  • thermoplastic resin fibers are arranged around the reinforced fiber to surround the reinforced fiber.
  • the at least two thermoplastic resin fibers are used as the resin fiber
  • the at least two thermoplastic resin fibers are arranged around the reinforced fiber to surround the reinforced fiber.
  • a hybrid resin fiber including the at least two thermoplastic resin fibers is provided around the long fiber.
  • the reinforced fiber/resin fiber composite having such a form is processed by thermoforming, then if the at least two thermoplastic resin fibers are suitably selected, the reinforced fiber can be reliably impregnated to the inside thereof with the thermoplastic resin, for example, when the thermoplastic resin fiber surrounding the reinforced fiber is melted, and at the same time, interfacial characteristics between the reinforced fiber and the thermoplastic resin can be improved. As a result, the reinforced fiber and the thermoplastic resin can be prevented from coming off the interface therebetween. Note that melting of the thermoplastic resin fiber during thermoforming, which is a type of so-called in-situ polymer blend, can be easily carried out.
  • the at least two thermoplastic resin fibers are preferably braided at a predetermined angle with respect to the longitudinal direction of the long fiber to form a braid around the reinforced fiber.
  • the long-fiber reinforced thermoplastic resin structure In order to improve the performance of the long-fiber reinforced thermoplastic resin structure, it may be effective to accurately control the composition of the long-fiber reinforced thermoplastic resin structure. For example, if the mixture ratio of the reinforced fiber and the thermoplastic resin or the composition ratio of the at least two thermoplastic resins can be flexibly controlled along the longitudinal direction of the reinforced fiber, the long-fiber reinforced thermoplastic resin structure as a final product can be manufactured in a form suitable for the purpose of use (“made-to-order” manufacture).
  • the at least two thermoplastic resin fibers are braided at a predetermined angle with respect to the longitudinal direction of the long fiber (reinforced fiber) to form a braid around the reinforced fiber.
  • the at least two thermoplastic resin fibers are braided around the reinforced fiber using a “braiding technique” which is known as a traditional craft.
  • strands (fiber) can be braided into various arrangement patterns by modifying the braiding pattern.
  • the braiding technique is applied to the reinforced fiber/resin fiber composite, the mixture ratio of the reinforced fiber and the thermoplastic resin, or the composition ratio of the at least two thermoplastic resins, can be flexibly controlled, depending on the pattern in which strands are braided.
  • the braiding technique is used, strands (fiber) are not opened, and therefore, the fiber is not likely to be damaged.
  • the braiding technique when a plurality of strands (fiber) are braided, the arrangement of the strands (fiber), and tension exerted on the strands (fiber), can be controlled on a strand-by-strand basis. Therefore, the reinforced fiber/resin fiber composite having this configuration is particularly effective in accurately controlling the structure and composition of the long-fiber reinforced thermoplastic resin structure as a final product. Therefore, if the braiding technique is used, the physical properties of each resin fiber can be imparted, in a desired form, to the long-fiber reinforced thermoplastic resin structure after thermoforming.
  • the at least two thermoplastic resin fibers are preferably selected to have complementary physical properties after thermoforming.
  • thermoforming is performed using the at least two thermoplastic resin fibers, the physical properties of the fibers complement each other.
  • a high-performance long-fiber reinforced thermoplastic resin structure which has a good balance between the physical properties of the fibers can be obtained.
  • the at least two thermoplastic resin fibers are preferably selected from the group consisting of a polylactic acid (PLA) fiber, polyamide (PA) fiber, polycarbonate (PC) fiber, polyoxymethylene (POM) fiber, polypropylene (PP) fiber, acid-modified polypropylene (MAPP) fiber, polyethylene (PE) fiber, polyphenylene sulfide (PPS) fiber, polyether ether ketone (PEEK) fiber, and polyether ketone ketone (PEKK) fiber.
  • PLA polylactic acid
  • PA polyamide
  • PC polycarbonate
  • POM polyoxymethylene
  • PP polypropylene
  • MAPP acid-modified polypropylene
  • PE polyethylene
  • PPS polyphenylene sulfide
  • PEEK polyether ether ketone
  • PEKK polyether ketone ketone
  • the at least two thermoplastic resin fibers are selected from the group consisting of a polylactic acid (PLA) fiber, polyamide (PA) fiber, polycarbonate (PC) fiber, polyoxymethylene (POM) fiber, polypropylene (PP) fiber, acid-modified polypropylene (MAPP) fiber, polyethylene (PE) fiber, polyphenylene sulfide (PPS) fiber, polyether ether ketone (PEEK) fiber, and polyether ketone ketone (PEKK) fiber. Therefore, if thermoforming is performed using the selected two thermoplastic resin fibers, a high-performance long-fiber reinforced thermoplastic resin structure which has advantages of the fibers can be obtained.
  • PPA polylactic acid
  • PA polyamide
  • PC polycarbonate
  • POM polyoxymethylene
  • PP polypropylene
  • MAPP acid-modified polypropylene
  • PE polyethylene
  • PPS polyphenylene sulfide
  • PEEK polyether ether ketone
  • PEKK polyether ketone
  • the at least two thermoplastic resin fibers are preferably a polypropylene (PP) fiber and an acid-modified polypropylene (MAPP) fiber.
  • the at least two thermoplastic resin fibers are a polypropylene (PP) fiber and an acid-modified polypropylene (MAPP) fiber.
  • PP polypropylene
  • MAPP acid-modified polypropylene
  • the at least two thermoplastic resin fibers are preferably a polylactic acid (PLA) fiber and a polyoxymethylene (POM) fiber.
  • the at least two thermoplastic resin fibers are a polylactic acid (PLA) fiber and a polyoxymethylene (POM) fiber.
  • PLA polylactic acid
  • POM polyoxymethylene
  • a method for manufacturing a reinforced fiber/resin fiber composite according to the present invention has the following characteristic features.
  • the method is a method for manufacturing a reinforced fiber/resin fiber composite which is an intermediate material for a long-fiber reinforced thermoplastic resin structure, in which the reinforced fiber is a long fiber extending in a longitudinal direction, and
  • the resin fiber includes at least two thermoplastic resin fibers, and
  • the method includes:
  • a hybrid resin fiber including the at least two thermoplastic resin fibers is provided around the long fiber.
  • the reinforced fiber/resin fiber composite having such a form is processed by thermoforming, then if the at least two thermoplastic resin fibers are suitably selected, the reinforced fiber can be reliably impregnated to the inside thereof with the thermoplastic resin, for example, when the thermoplastic resin fiber surrounding the reinforced fiber is melted, and at the same time, interfacial characteristics between the reinforced fiber and the thermoplastic resin can be improved. As a result, the reinforced fiber and the thermoplastic resin can be prevented from coming off the interface therebetween. Note that melting of the thermoplastic resin fiber during thermoforming, which is a type of so-called in-situ polymer blend, can be easily carried out.
  • the method for manufacturing the reinforced fiber/resin fiber composite having this configuration employs a “braiding technique” which is known as a traditional craft.
  • strands (fiber) can be braided into various arrangement patterns by modifying the braiding pattern. Therefore, if the braiding technique is applied to the reinforced fiber/resin fiber composite manufacturing method, the mixture ratio of the reinforced fiber and the thermoplastic resin, or the composition ratio of the at least two thermoplastic resins, can be flexibly controlled, depending on the pattern in which strands are braided. In addition, if the braiding technique is used, strands (fiber) are not opened, and therefore, the fiber is not likely to be damaged.
  • the braiding technique when a plurality of strands (fiber) are braided, the arrangement of the strands (fiber), and tension exerted on the strands (fiber), can be controlled on a strand-by-strand basis. Therefore, the method for manufacturing the reinforced fiber/resin fiber composite having this configuration is particularly effective in accurately controlling the structure and composition of the long-fiber reinforced thermoplastic resin structure as a final product. Therefore, if the braiding technique is used, the physical properties of each resin fiber can be imparted, in a desired form, to the long-fiber reinforced thermoplastic resin structure after thermoforming.
  • FIG. 1( a ) is a schematic diagram showing an example braiding machine for manufacturing a reinforced fiber/resin fiber composite according to the present invention
  • FIG. 1( b ) is an external view of the reinforced fiber/resin fiber composite.
  • FIG. 2 is a schematic cross-sectional view of a reinforced fiber/resin fiber composite for describing a pattern in which a PP fiber and an MAPP fiber (braiding fibers) are braided with respect to a carbon fiber (axial fiber), showing a double-layer arrangement ( FIG. 2( a )) and an alternate arrangement ( FIG. 2( b )).
  • FIG. 3 shows a photograph of an external appearance of a carbon fiber/resin fiber composite of an example in which two thermoplastic resin fibers are braided with respect to a carbon fiber, and a diagram showing a structure thereof.
  • FIG. 4 shows photographs of cross-sections of test pieces having a double-layer arrangement and an alternate arrangement, indicating changes in their impregnated states depending on the molding time.
  • FIG. 5 shows example image data for calculating the unimpregnation ratio of a carbon fiber, indicating a cross-section of a test piece before image processing ( FIG. 5( a )) and that after image processing ( FIG. 5( b )).
  • FIG. 6 is a graph plotted to show a relationship between the unimpregnation ratio and molding time of each of test pieces having the double-layer and alternate arrangements.
  • FIG. 7 is a graph of measurement data (load-flexure curve) of each test piece which was obtained by a three point bending test.
  • FIGS. 1 to 6 Embodiments of a reinforced fiber/resin fiber composite according to the present invention and a method for manufacturing the composite will now be described with reference to FIGS. 1 to 6 . Note that the present invention is not intended to be limited to configurations described in the embodiments below and the accompanying drawings.
  • a reinforced fiber/resin fiber composite according to the present invention which is an intermediate material for a long-fiber reinforced thermoplastic resin structure is provided in the form of a composite or mixture including a long fiber and a thermoplastic resin fiber.
  • the long fiber includes a multifilament, which is a group of monofilaments.
  • the multifilament is a thin and long fiber extending in the longitudinal direction.
  • the long fiber may, for example, be a reinforced fiber (e.g., a carbon fiber, glass fiber, aramid fiber, etc.).
  • the thermoplastic resin fiber includes at least two fibers. It is desirable to select a combination of thermoplastic resin fibers which have complementary physical properties after thermoforming. For example, a combination of thermoplastic resin fibers is selected so that good impregnation characteristics and good interfacial characteristics are simultaneously provided by thermoforming.
  • a polypropylene (PP) fiber which is representative of a thermoplastic resin fiber, has good resin impregnation characteristics and slightly poor interfacial characteristics (e.g., interfacial shear strength).
  • a PP fiber is modified with an acid to form an acid-modified polypropylene (MAPP) fiber
  • MAPP acid-modified polypropylene
  • the interfacial characteristics are improved, and at the same time, the wettability deteriorates, and therefore, the thermoplastic resin impregnation characteristics decrease. Therefore, a PP fiber and an MAPP fiber are combined into a new hybrid resin fiber having both types of characteristics.
  • the fibers offset mutual lacks of physical properties, so that good impregnation characteristics and good interfacial characteristics are simultaneously achieved, and therefore, a material having both good impregnation characteristics and good interfacial characteristics can be provided.
  • thermoplastic resin fibers are provided around the long fiber (reinforced fiber) to surround the long fiber in order to form a hybrid.
  • the term “surround” with respect to the long fiber means that the at least two thermoplastic resin fibers are provided on the surface of the long fiber, overlapping each other, so that all or a portion of the surface of the long fiber is concealed from the outside.
  • the term “provided around” or “arranged around” with respect to the long fiber means that, in a cross-sectional view of the fiber, the outlines of the at least two thermoplastic resin fibers are in contact with or close to the outline of the long fiber.
  • the arrangement of the at least two thermoplastic resin fibers with respect to the long fiber is not limited to an arrangement in which the at least two thermoplastic resin fibers extend generally in parallel to the long fiber in the longitudinal direction.
  • the at least two thermoplastic resin fibers may extend at a predetermined angle with respect to the long fiber, may be bent or curved and extend while gradually changing the position, or may be randomly positioned.
  • the hybrid resin fiber including the at least two thermoplastic resin fibers only needs to be provided around the long fiber.
  • a braiding technique is known as a Japanese traditional craft, in which a plurality of thin threads (braiding fiber strands) are interwoven into a fabric which is strong and has a beautiful woven pattern.
  • a braided fabric is provided in which at least two thermoplastic resin fibers which are braiding fibers are arranged around a reinforced fiber which is an axial fiber. Specifically, the at least two thermoplastic resin fibers are interwoven at a predetermined angle with respect to the longitudinal direction of the reinforced fiber to form a braid in which the at least two resin fibers are braided around the reinforced fiber.
  • FIG. 1( a ) is a schematic diagram showing an example braiding machine 100 for manufacturing a reinforced fiber/resin fiber composite 50 of the present invention.
  • FIG. 1 ( b ) is an external view of the reinforced fiber/resin fiber composite 50 .
  • the braiding machine 100 includes axial fiber supply units 10 which supply an axial fiber strand (reinforced fiber) 15 to a core fiber (reinforced fiber) 40 which is a core of a braided fabric (the reinforced fiber/resin fiber composite 50 ), and braiding fiber supply units 20 which supply a braiding fiber strand (resin fiber) 25 to the core fiber 40 .
  • the braiding fiber supply units 20 Prior to formation of a braided fabric, for preparation, the braiding fiber supply units 20 are on standby around the axial fiber supply unit 10 .
  • the axial fiber supply units 10 and the braiding fiber supply units 20 are provided in pairs. In FIG. 1( a ), the axial fiber supply units 10 are each paired with one braiding fiber supply unit 20 .
  • the axial fiber supply unit 10 may be each combined with a plurality of braiding fiber supply units 20 .
  • the number of the braiding fiber supply units 20 may be suitably set based on the structural design of the reinforced fiber/resin fiber composite 50 .
  • the axial fiber supply unit 10 is connected to a roving (not shown) into which the reinforced fiber is wound, and outputs the reinforced fiber unwound from the roving through a tip portion 11 as the axial fiber strand 15 .
  • the braiding fiber supply unit 20 includes a spindle 21 around which the braiding fiber strand 25 is wound, and an unwinding bar 22 through which the braiding fiber strand 25 pulled out of the spindle 21 is passed.
  • the braiding fiber supply unit 20 revolves around the corresponding axial fiber supply unit 10 . In this case, the relative positions of the spindle 21 and the unwinding bar 22 as viewed from above change.
  • the braiding fiber strand 25 wound around the spindle 21 is continuously released from the spindle 21 through the unwinding bar 22 .
  • the released braiding fiber strands 25 are collected to surround the axial fiber strands 15 , and the axial fiber supply units 10 and the braiding fiber supply units 20 move on a braiding orbit 30 , so that the braiding fiber strands 25 are braided at a braiding angle ⁇ with respect to the longitudinal direction of the axial fiber strands 15 , and therefore, a braid is formed.
  • the braid formed by the axial fiber strands 15 and the braiding fiber strands 25 surrounds the core fiber 40 .
  • the reinforced fiber/resin fiber composite 50 (also referred to as a “hybrid fiber composite”) as a braided fabric shown in FIG. 1( b ) in which the braiding fiber strands 25 are braided at the braiding angle ⁇ with respect to the axial fiber strands 15 is continuously formed around the core fiber 40 .
  • the resultant reinforced fiber/resin fiber composite 50 is processed by thermoforming directly or after being arranged in a desired shape, to obtain the desired long-fiber reinforced thermoplastic resin structure. Melting of the resin fiber during thermoforming, which is a type of so-called in-situ polymer blend, can be easily carried out.
  • the pattern in which the braiding fiber strands 25 are braided with respect to the axial fiber strands 15 may be modified to provide various arrangement patterns of the braiding fiber strands (thermoplastic resin fiber) 25 . Therefore, If the braiding technique is applied to the reinforced fiber/resin fiber composite 50 of the present invention, the mixture ratio of the reinforced fiber and the thermoplastic resin, and the composition ratio of the thermoplastic resin melted by heat, can be flexibly controlled by the pattern in which the strands are braided. As a result, the long-fiber reinforced thermoplastic resin structure as a final product can be manufactured in a form suitable for the purpose of use (“made-to-order” manufacture).
  • the fibers are not opened, and therefore, are not likely to be damaged.
  • the braiding technique when a plurality of braiding fiber stands are braided, the arrangement of the braiding fiber strands, and tension exerted on the braiding fiber strands, can be controlled on a strand-by-strand basis. Therefore, the braiding technique is particularly effective in accurately controlling the structure and composition of the long-fiber reinforced thermoplastic resin structure as a final product. Therefore, if the braiding technique is used, the physical properties of each resin fiber can be imparted, in a desired form, to the long-fiber reinforced thermoplastic resin structure after thermoforming.
  • a carbon fiber is used as the long fiber which is a reinforced fiber
  • a polypropylene (PP) fiber and an acid-modified polypropylene (MAPP) fiber which is obtained by modifying a PP fiber by maleic acid are used as the thermoplastic resin fibers.
  • a PP fiber has good resin impregnation characteristics and slightly poor interfacial characteristics (e.g., interfacial shear strength).
  • an MAPP fiber has slightly poor resin impregnation characteristics and good interfacial characteristics.
  • FIG. 2 is a schematic cross-sectional view of the reinforced fiber/resin fiber composite 50 for describing a pattern in which a PP fiber 25 a and an MAPP fiber 25 b (the braiding fiber strands 25 ) are braided with respect to a carbon fiber 15 a (the axial fiber strand 15 ).
  • 16 strands of the PP fiber 25 a and 16 strands of the MAPP fiber 25 b were braided with respect to one strand of the carbon fiber 15 a to obtain a carbon fiber/PP fiber/MAPP fiber composite (hybrid fiber composite) which is an intermediate material for a long-fiber reinforced thermoplastic resin structure.
  • the resin fibers were braided in two patterns shown in FIGS.
  • FIG. 2( a ) only the PP fiber strands 25 a are braided as a first layer to surround the surface of the carbon fiber 15 a , and next, only the MAPP fiber strands 25 b are braided as a second layer on the first layer.
  • the braiding pattern of FIG. 2( a ) is referred to as “double-layer arrangement.” In FIG.
  • FIG. 2( b ) shows a photograph of an external appearance of the carbon fiber/resin fiber composite of this example in which two thermoplastic resin fibers having different properties are braided with respect to a carbon fiber, and a diagram showing a structure thereof.
  • thermoplastic resin structure also referred to as a “hybrid structure”
  • a carbon fiber/resin fiber composite hybrid fiber composite
  • thermoforming carbon fiber/resin fiber composites having the double-layer arrangement and the alternate arrangement were each processed by thermoforming to obtain test pieces of a long-fiber (carbon fiber) reinforced thermoplastic resin structure (hybrid structure).
  • the thermoforming for each test piece was performed under conditions that the molding temperature was 200° C., the molding pressure was 10 MPa, and the molding time was 5 min, 10 min, 20 min, and 40 min.
  • a cross-section of each test piece was observed to evaluate how much (or how little) the carbon fiber was impregnated with the thermoplastic resin.
  • FIG. 4 shows photographs of cross-sections of the test pieces having the double-layer and alternate arrangements, indicating changes in their impregnated states depending on the molding time.
  • a numerical value described at the right corner of each photograph represents the unimpregnation ratio of the carbon fiber.
  • the unimpregnation ratio is calculated by a procedure described below.
  • FIG. 5 shows example image data for calculating the unimpregnation ratio of the carbon fiber.
  • FIGS. 5( a ) and 5 ( b ) show cross-sections of a test piece before and after image processing, respectively.
  • the cross-sectional image of the carbon fiber (a bundle of fiber strands) of FIG. 5( a ) is binarized by image processing using a predetermined threshold, to obtain the cross-sectional image of FIG. 5( b ) having an impregnated region S 1 indicated by a white region and an unimpregnated region S 2 indicated by a black region.
  • the unimpregnation ratio (%) is calculated using the values of S 1 and S 2 obtained from the cross-sectional image of FIG. 5( b ) by:
  • FIG. 6 is a graph plotted to show a relationship between the unimpregnation ratio and molding time of each of the test pieces having the double-layer and alternate arrangements.
  • the unimpregnation ratio of the thermoplastic resin with respect to the carbon fiber gradually decreases with molding time. In other words, it was observed that the carbon fiber is more sufficiently impregnated with the thermoplastic resin with an increase in the molding time.
  • the double-layer arrangement has impregnation characteristics better than those of the alternate arrangement.
  • the carbon fiber/resin fiber composite having the double-layer arrangement is subjected to thermoforming for 20 min or more, preferably 40 min or more, the carbon fiber can be impregnated to substantially the center thereof with the thermoplastic resin.
  • a three point bending test was conducted using a flexure tester on a long-fiber reinforced thermoplastic resin structure (hybrid structure) which is obtained by processing a carbon fiber/resin fiber composite (hybrid fiber composite) by thermoforming, to evaluate the interfacial characteristics thereof.
  • Mechanical characteristics in the longitudinal direction of the long-fiber reinforced thermoplastic resin structure were measured using the three point bending test.
  • the interfacial characteristics can be indirectly estimated to be better with an increase in the values of the modulus of elasticity and strength.
  • Long-fiber reinforced thermoplastic resin structures in the shape of a plate having a length of 50 mm, a width of 20 mm, and a thickness of 2 mm were produced as test pieces by thermoforming.
  • As the test pieces molded products of carbon fiber/resin fiber composites having the double-layer and alternate arrangements of FIG. 2 were prepared.
  • As control test pieces molded products of a carbon fiber/PP fiber composite and a carbon fiber/MAPP fiber composite were prepared. The test pieces were produced by thermoforming under conditions that the molding temperature was 200° C., the molding pressure was 10 MPa, and the molding time was 5 min, 10 min, 20 min, and 40 min.
  • FIG. 7 is a graph of measurement data (load-flexure curve) of each test piece which was obtained by the three point bending test.
  • the modulus of elasticity in bending E (MPa) and flexural stress ⁇ (MPa) of each test piece were estimated using the following expressions (2) and (3) based on the measurement data.
  • the maximum value of the flexural stress ⁇ is defined as a flexural strength. Note that these calculations were performed using a technique complying with JIS K7017.
  • the long-fiber reinforced thermoplastic resin structures (hybrid structures) formed of the carbon fiber/resin fiber composite having the double-layer arrangement (Test No. 1) and the carbon fiber/resin fiber composite having the alternate arrangement (Test No. 2) have a modulus of elasticity and strength much greater than those of the long-fiber reinforced thermoplastic resin structure (non-hybrid structure) formed of the carbon fiber/PP fiber composite (Test No. 3).
  • the carbon fiber/resin fiber composite of the double-layer arrangement (Test No. 1) has a modulus of elasticity and strength similar to those of the carbon fiber/MAPP fiber composite (Test No. 4).
  • a carbon fiber/resin fiber composite which includes a hybrid of a PP fiber and an MAPP fiber as the resin fiber is processed by thermoforming, a high-performance long-fiber reinforced thermoplastic resin structure having a sufficient strength in the long fiber direction (longitudinal direction) can be obtained with as high interfacial characteristics as those of a carbon fiber/MAPP fiber composite while reducing a decrease in the impregnation characteristics due to the MAPP fiber.
  • the at least two resin fibers included in the carbon fiber/resin fiber composite may be a combination of other materials in addition to a PP fiber and an MAPP fiber described in the above embodiment.
  • Example resin fiber composites having a combination of resin fibers, and their complementary physical properties (physical properties which can be simultaneously achieved), are described as follows.
  • a polylactic acid (PLA) fiber/a polyoxymethylene (POM) fiber interfacial characteristics and impregnation characteristics/toughness
  • a polypropylene (PP) fiber/a polyamide (PA) fiber (nylon fiber): impregnation characteristics/interfacial adhesiveness, low cost/interfacial adhesiveness
  • a polyamide (PA) fiber/a polyoxymethylene (POM) fiber interfacial adhesiveness/abrasion resistance and slidability
  • a polypropylene (PP) fiber/a polyoxymethylene (POM) fiber impregnation characteristics/abrasion resistance and slidability
  • a polyamide (PA) fiber/a polyphenylene sulfide (PPS) fiber interfacial adhesiveness/heat resistance, interfacial adhesiveness/impregnation characteristics
  • a polypropylene (PP) fiber/a polycarbonate (PC) fiber impregnation characteristics/impact resistance
  • a polyamide (PA) fiber/a polycarbonate (PC) fiber interfacial adhesiveness/impact resistance
  • the at least two resin fibers included in the resin fiber composite may, for example, be a thermoplastic resin fiber, such as a polyethylene (PE) fiber, polyether ether ketone (PEEK) fiber, polyether ketone ketone (PEKK) fiber, etc.
  • a thermoplastic resin fiber such as a polyethylene (PE) fiber, polyether ether ketone (PEEK) fiber, polyether ketone ketone (PEKK) fiber, etc.
  • PE polyethylene
  • PEEK polyether ether ketone
  • PEKK polyether ketone ketone
  • a hybrid fiber composite produced by the braiding technique may have a variety of structures depending on the intended long-fiber reinforced thermoplastic resin structure.
  • a hybrid fiber composite may be constructed on the basis of these braids. For example, when a pillar which is a part of the body of an automobile is manufactured, a reinforced fiber/resin fiber composite which is an intermediate material is produced in the form of a ribbon-like flat braid, and is wound into an annular shape. As a result, a hollow pillar having a light weight and a high strength can be manufactured.
  • a braided fabric (reinforced fiber/resin fiber composite) is produced using the core fiber 40 and the axial fiber strand 15 which are a reinforced fiber and the braiding fiber strand 25 which is a resin fiber.
  • the fiber types of the core fiber 40 , the axial fiber strand 15 , and the braiding fiber strand 25 are not particularly limited, and may be suitably determined, depending on the reinforced fiber/resin fiber composite to be produced.
  • the axial fiber strand 15 may be a reinforced fiber while the core fiber 40 and the braiding fiber strand 25 may be a resin fiber.
  • the reinforced fiber/resin fiber composite of the present invention serves as an intermediate material for a long-fiber reinforced thermoplastic resin structure, and is preferably applicable to the fields of automobiles, ships, aircrafts, etc.

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US9809707B2 (en) 2015-05-29 2017-11-07 Hyundai Motor Company Polymer resin composition, polymer composite tape, and front bumper of automobile
US9839253B2 (en) 2014-12-10 2017-12-12 Nike, Inc. Last system for braiding footwear
US10060057B2 (en) 2015-05-26 2018-08-28 Nike, Inc. Braiding machine with non-circular geometry
US10060056B1 (en) * 2015-05-04 2018-08-28 A&P Technology, Inc. Interlocking braided structures
US10167582B1 (en) * 2016-05-13 2019-01-01 Stryker Corporation Braided filament with particularized strand compositions and methods of manufacturing and using same
US10238176B2 (en) 2015-05-26 2019-03-26 Nike, Inc. Braiding machine and method of forming a braided article using such braiding machine
US10280538B2 (en) 2015-05-26 2019-05-07 Nike, Inc. Braiding machine and method of forming an article incorporating a moving object
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US20210238013A1 (en) * 2020-01-30 2021-08-05 Cortland Company, Inc. Sling
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US10060056B1 (en) * 2015-05-04 2018-08-28 A&P Technology, Inc. Interlocking braided structures
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US10060057B2 (en) 2015-05-26 2018-08-28 Nike, Inc. Braiding machine with non-circular geometry
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US20170037548A1 (en) * 2015-08-07 2017-02-09 Nike, Inc. Braiding Machine With Multiple Rings Of Spools
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US11890800B2 (en) 2017-06-15 2024-02-06 Arkema Inc. Production of semicrystalline parts from pseudo-amorphous polymers
US11390008B2 (en) 2017-06-15 2022-07-19 Arkema Inc. Production of semicrystalline parts from pseudo-amorphous polymers
US11623847B2 (en) * 2020-01-30 2023-04-11 Cortland Company, Inc. Sling
US20210238013A1 (en) * 2020-01-30 2021-08-05 Cortland Company, Inc. Sling
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