WO2013042763A1 - 強化繊維/樹脂繊維複合体、及びその製造方法 - Google Patents
強化繊維/樹脂繊維複合体、及びその製造方法 Download PDFInfo
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- WO2013042763A1 WO2013042763A1 PCT/JP2012/074200 JP2012074200W WO2013042763A1 WO 2013042763 A1 WO2013042763 A1 WO 2013042763A1 JP 2012074200 W JP2012074200 W JP 2012074200W WO 2013042763 A1 WO2013042763 A1 WO 2013042763A1
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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
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- 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
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- 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
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- 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
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- 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
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- 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 a reinforcing fiber / resin fiber composite as an intermediate material of a long fiber reinforced thermoplastic resin structure and a method for producing the same.
- Fiber-reinforced thermoplastic resins combining thermoplastic resins and fibers are used in various fields by taking advantage of the excellent characteristics of light weight and high strength. For example, in transportation machines such as automobiles, ships, and airplanes, improvement of fuel consumption and safety is achieved by using a molded product of fiber reinforced thermoplastic resin as a part of a part.
- a fiber reinforced thermoplastic resin As such a fiber reinforced thermoplastic resin, a fiber reinforced plastic (FRP) obtained by adding a short fiber to a thermoplastic resin has been well known.
- a thermoplastic resin and a long fiber for example, carbon Attention has been focused on long fiber reinforced thermoplastic resins in combination with reinforced fibers such as fibers.
- the “long fiber” in the present specification means a fiber (so-called “yarn”) extending in the longitudinal direction.
- the long fiber reinforced thermoplastic resin is (1) very excellent in impact resistance, (2) excellent in recyclability because it can be melted by heat, and (3) in a short time because it does not undergo chemical changes during molding.
- the long fiber reinforced thermoplastic resin has a problem that it is difficult to impregnate the long fiber with the thermoplastic resin because the melt viscosity of the thermoplastic resin is very high.
- the impregnation characteristics of the resin are deteriorated, sufficient strength cannot be expressed in the molded product.
- the impregnation characteristics of the thermoplastic resin into the long fibers and the interface characteristics between the long fibers and the thermoplastic resin are generally contradictory characteristics.
- the contact angle of the thermoplastic resin with respect to the long fiber increases (that is, the wettability of the surface of the long fiber deteriorates).
- the impregnation property decreases.
- the impregnation characteristics and the interface characteristics are in a trade-off relationship.
- the impregnation characteristics and the interface characteristics are It is desirable to make them compatible as much as possible.
- an intermediate material used to produce the long fiber reinforced thermoplastic resin structure It is considered effective to devise the form of.
- the arrangement and blending of the long fibers and the thermoplastic resin can be adjusted before thermoforming, so that it is easy to control the characteristics of the finished long fiber reinforced thermoplastic resin structure.
- the “intermediate material” means a composite or mixture of long fibers and a thermoplastic resin.
- thermoplastic resin tape As an intermediate material for long fiber reinforced thermoplastic resin structures, for example, "carbon fiber reinforced thermoplastic resin tape” has been developed in which a long fiber is impregnated with a thermoplastic resin into a tape shape.
- carbon fiber reinforced thermoplastic resin tape In Patent Document 1, carbon fiber strands that have been defibrated are immersed in a molten thermoplastic resin bath to impregnate the carbon fibers with a thermoplastic resin, and then the carbon fibers after resin impregnation are used as molding nozzles. By passing it, an elongated carbon fiber reinforced thermoplastic resin tape is formed.
- the carbon fiber reinforced thermoplastic resin tape is used, for example, by winding it around the surface of a structure to be applied and melting it, and then cooling and solidifying it. As a result, the structure is reinforced.
- a “mixed yarn for composite materials” in which continuous reinforcing fiber bundles and continuous thermoplastic resin fiber bundles, which are long fibers, are mixed is also known.
- Patent Document 2 After performing a disentanglement process to the untwisted continuous reinforcing fiber bundle and the untwisted continuous thermoplastic resin fiber bundle, respectively, the two are mixed to obtain a mixed fiber for composite material. It has gained.
- the composite yarn for composite material for example, one processed into a woven or knitted form is used.
- the carbon fiber reinforced thermoplastic resin tape of Patent Document 1 long fibers impregnated with a thermoplastic resin extend substantially in parallel along the longitudinal direction. For this reason, the blending ratio of the long fibers and the thermoplastic resin becomes substantially constant at an arbitrary position of the tape. With such an intermediate material in which the blending ratio is substantially fixed, the composition of the long fiber reinforced thermoplastic resin structure as a finished product cannot be precisely controlled depending on the location. Moreover, since it is difficult to control the composition, it is considered difficult to achieve both the impregnation characteristics of the long fibers and the interface characteristics between the long fibers and the thermoplastic resin. Furthermore, the carbon fiber reinforced thermoplastic resin tape can be applied only to a target structure having a flat surface or a simple curved surface.
- the continuous reinforcing fiber bundle and the continuous thermoplastic resin fiber bundle are simply mixed, the blending ratio of both is precisely controlled along the longitudinal direction. It is difficult. Accordingly, even in Patent Document 2, it is not possible to achieve both the impregnation characteristics of long fibers and the interface characteristics between the long fibers and the thermoplastic resin. Further, the reinforcing fibers may be damaged by friction during the defibrating process of the continuous reinforcing fiber bundle or during the fiber mixing operation of the continuous reinforcing fiber bundle and the continuous thermoplastic resin fiber bundle. Each fiber may be damaged when the composite yarn for composite material is processed into a woven fabric or a knitted fabric. Furthermore, when producing a mixed fiber for composite materials, a part of the fiber may be lost by cutting and dropping during the defibration and blending operations. In such a case, the yield of the final product may be lost. Decreases.
- a reinforced fiber / resin fiber composite as an optimum intermediate material composed of a reinforced fiber and a resin fiber has not been developed yet.
- the present invention has been made in view of the above problems, and in order to achieve both different physical properties (for example, impregnation characteristics and interface characteristics) of fibers and resins, the long fibers and the thermoplastic resin fibers in the intermediate material It is an object of the present invention to provide a reinforced fiber / resin fiber composite in which the ratio of the two and the arrangement of both are precisely controlled. Moreover, it aims at establishing the manufacturing method which manufactures such a reinforced fiber / resin fiber composite body efficiently, reliably, and at low cost.
- the characteristic configuration of the reinforced fiber / resin fiber composite according to the present invention for solving the above problems is as follows: A reinforced fiber / resin fiber composite as an intermediate material for a long fiber reinforced thermoplastic resin structure,
- the reinforcing fiber is a long fiber extending in the longitudinal direction,
- the resin fiber has at least two kinds of thermoplastic resin fibers,
- the at least two kinds of thermoplastic resin fibers are arranged around the reinforcing fibers so as to surround the reinforcing fibers.
- the interfacial property between the long fiber and the thermoplastic resin is improved while improving the impregnation property of the long fiber. It is important to maintain.
- it is considered effective to devise the form of the reinforcing fiber / resin fiber composite as an intermediate material.
- the reinforcing fiber / resin fiber composite of this configuration in the case of using long fibers extending in the longitudinal direction as reinforcing fibers, and when using at least two types of thermoplastic resin fibers as resin fibers, At least two kinds of thermoplastic resin fibers are arranged around the reinforcing fibers so as to surround the reinforcing fibers.
- thermoplastic resin fibers containing at least two types of thermoplastic resin fibers around the long fibers.
- thermoplastic resin fibers are appropriately selected as at least two types of thermoplastic resin fibers, for example, the thermoplastic resin fibers surrounding the reinforcing fibers are melted.
- thermoplastic resin fibers surrounding the reinforcing fibers are melted.
- the melting of the thermoplastic resin fiber during the thermoforming is a kind of so-called in-situ polymer blend and can be easily performed.
- the at least two kinds of thermoplastic resin fibers are arranged around the reinforcing fibers in a braid state in which the fibers are combined with each other at a predetermined angle with respect to the longitudinal direction of the long fibers.
- the long fiber reinforced thermoplastic resin structure In order to achieve higher performance of the long fiber reinforced thermoplastic resin structure, it is considered effective to precisely control the composition of the long fiber reinforced thermoplastic resin structure. For example, if the blending ratio of the reinforcing fiber and the thermoplastic resin and the composition ratio of at least two thermoplastic resins can be freely controlled along the longitudinal direction of the reinforcing fiber, the long fiber reinforced heat that is the finished product can be controlled. It becomes possible to manufacture the plastic resin structure in a form (made to order) according to the purpose of use. In this regard, according to the reinforcing fiber / resin fiber composite of this configuration, in a braid state in which at least two kinds of thermoplastic resin fibers are combined with each other at a predetermined angle with respect to the longitudinal direction of the long fibers (reinforcing fibers).
- the braiding technique when a plurality of strings (fibers) are assembled, the arrangement of the strings (fibers) and the tension acting on the strings (fibers) can be controlled one by one. For this reason, the reinforced fiber / resin fiber composite of this configuration is particularly effective when it is necessary to precisely control the structure and composition of the finished long fiber reinforced thermoplastic resin structure. Therefore, if the braid technology is used, the physical properties of each resin fiber can be imparted to the long fiber reinforced thermoplastic resin structure after thermoforming in a desired state.
- thermoplastic resin fibers are preferably selected so that the physical properties of the fibers are complemented each other after thermoforming.
- the reinforced fiber / resin fiber composite of this configuration when thermoforming using at least two types of thermoplastic resin fibers, the physical properties of each fiber are complemented with each other, so the physical properties of each fiber are balanced. It is possible to obtain a high-performance long fiber reinforced thermoplastic resin structure that is well combined.
- thermoplastic resin fibers include polylactic acid (PLA) fiber, polyamide (PA) fiber, polycarbonate (PC) fiber, polyoxymethylene (POM) fiber, polypropylene (PP) fiber, and acid-modified polypropylene (MAPP). It is preferably selected from the group consisting of fibers, polyethylene (PE) fibers, polyphenylene sulfide (PPS) fibers, polyether ether ketone ketone (PEEK) fibers, and polyether ketone ketone (PEKK) fibers.
- PPA polyamide
- PC polycarbonate
- POM polyoxymethylene
- PP polypropylene
- MAPP acid-modified polypropylene
- PE polyethylene
- PPS polyphenylene sulfide
- PEEK polyether ether ketone ketone
- PEKK polyether ketone ketone
- thermoplastic resin fibers are polylactic acid (PLA) fiber, polyamide (PA) fiber, polycarbonate (PC) fiber, and polyoxymethylene (POM) fiber.
- 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 ketone
- thermoplastic resin fibers are preferably polypropylene (PP) fibers and acid-modified polypropylene (MAPP) fibers.
- polypropylene (PP) fiber and acid-modified polypropylene (MAPP) fiber are adopted as at least two kinds of thermoplastic resin fibers.
- PP polypropylene
- MAPP acid-modified polypropylene
- thermoplastic resin fibers are preferably polylactic acid (PLA) fibers and polyoxymethylene (POM) fibers.
- polylactic acid (PLA) fiber and polyoxymethylene (POM) fiber are adopted as at least two kinds of thermoplastic resin fibers.
- PLM polyoxymethylene
- the characteristic configuration of the method for producing a reinforced fiber / resin fiber composite according to the present invention for solving the above problems is as follows: A method for producing a reinforced fiber / resin fiber composite as an intermediate material of a long fiber reinforced thermoplastic resin structure,
- the reinforcing fiber is a long fiber extending in the longitudinal direction,
- the resin fiber has at least two kinds of thermoplastic resin fibers,
- a preparatory step in which the at least two types of thermoplastic resin fibers stand by around the reinforcing fibers;
- the same operational effects as the above-described reinforcing fiber / resin fiber composite can be achieved. That is, when thermoforming is performed using a reinforcing fiber / resin fiber composite in which a hybridized resin fiber containing at least two types of thermoplastic resin fibers exists around the long fiber, at least two types of heat If the thermoplastic resin fiber is appropriately selected, for example, when the thermoplastic resin fiber surrounding the reinforcing fiber is melted, the interface between the reinforcing fiber and the thermoplastic resin is surely impregnated into the reinforcing fiber. Characteristics can be improved. As a result, it is possible to prevent the interface peeling between the two.
- the melting of the thermoplastic resin fiber during the thermoforming is a kind of so-called in-situ polymer blend and can be easily performed.
- the manufacturing method of the reinforced fiber / resin fiber composite of this structure utilizes the “braid technology” known as a traditional craft.
- the braiding technique the arrangement form of the strings (fibers) can be realized in various patterns by devising how to assemble the strings (fibers). Therefore, if braid technology is applied to the production of reinforced fiber / resin fiber composites, the blending ratio of reinforced fiber and thermoplastic resin and the composition ratio of at least two thermoplastic resins can be freely controlled by the way of assembling the yarn. It becomes possible to do.
- the string (fiber) is not defibrated, so that the fiber is not damaged.
- the braiding technique when a plurality of strings (fibers) are assembled, the arrangement of the strings (fibers) and the tension acting on the strings (fibers) can be controlled one by one. For this reason, the manufacturing method of the reinforced fiber / resin fiber composite of this configuration is particularly effective when it is necessary to precisely control the structure and composition of the finished long fiber reinforced thermoplastic resin structure. Therefore, if the braid technology is used, the physical properties of each resin fiber can be imparted to the long fiber reinforced thermoplastic resin structure after thermoforming in a desired state.
- FIG. 1A is a schematic view showing an example of an assembly making machine for producing a reinforced fiber / resin fiber composite of the present invention
- FIG. 1B 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 explaining how to assemble PP fiber and MAPP fiber (braid) with respect to carbon fiber (center yarn), (a) two-layer arrangement, and ( b) It is a figure which shows alternate arrangement
- FIG. 3 is an appearance photograph and a structural diagram of a carbon fiber / resin fiber composite of an example in which two types of thermoplastic resin fibers are assembled with respect to carbon fibers.
- FIG. 2 is a schematic cross-sectional view of a reinforced fiber / resin fiber composite for explaining how to assemble PP fiber and MAPP fiber (braid) with respect to carbon fiber (center yarn), (a) two-layer arrangement, and ( b) It is a figure which shows alternate arrangement
- FIG. 4 is a cross-sectional photograph of the test piece showing the change in the impregnation state depending on the molding time for the two-layer arrangement and the alternate arrangement.
- FIG. 5 is an example of image data for obtaining the unimpregnated ratio in the carbon fiber, and shows (a) a cross section of the test piece before image processing and (b) a cross section after image processing.
- FIG. 6 is a graph in which the unimpregnated ratio of each test piece in the two-layer arrangement and the alternate arrangement is plotted with respect to the molding time.
- FIG. 7 is a graph of measurement data (load-deflection curve) by a three-point bending test of each test piece.
- the reinforcing fiber / resin fiber composite of the present invention which is an intermediate material of the long fiber reinforced thermoplastic resin structure, is configured as a composite or mixture containing long fibers and thermoplastic resin fibers.
- Long fibers are composed of multifilaments that are aggregates of monofilaments, and elongated multifilaments extend in the longitudinal direction to form a yarn.
- Reinforcing fibers for example, carbon fibers, glass fibers, aramid fibers, etc. can be used for the long fibers.
- thermoplastic resin fibers At least two kinds of fibers are used for the thermoplastic resin fibers. It is desirable to select a combination of thermoplastic resin fibers so that the physical properties of the fibers are mutually complemented after thermoforming. For example, it is selected so that the impregnation property and the interface property are compatible by thermoforming.
- polypropylene (PP) fibers which are typical thermoplastic resin fibers, are excellent in resin impregnation properties, but have slightly poor interface characteristics (for example, interface shear strength).
- MAPP polypropylene
- PP resin and MAPP fiber are combined and hybridized to form a new resin fiber having both characteristics.
- the lack of physical properties of each fiber is complemented with each other, so that it is possible to realize a material that has both impregnation properties and interface properties and is excellent in both properties.
- thermoplastic resin fibers are arranged around the long fibers so as to surround the long fibers (reinforcing fibers) for hybridization.
- “encloses the long fiber” means that at least two types of thermoplastic resin fibers are present so as to overlap the surface of the long fiber, and a part or all of the surface of the long fiber cannot be seen from the outside. It means to make.
- “arranged around the long fibers” means a state in which the contours of at least two types of thermoplastic resin fibers are in contact with or in the vicinity of the contours of the long fibers in a cross-sectional view of the fibers.
- the arrangement form of the at least two types of thermoplastic resin fibers with respect to the long fibers is not limited to extending substantially parallel to each other in the longitudinal direction.
- at least two types of thermoplastic resin fibers with respect to the long fibers are predetermined. It may extend at an angle, or at least two types of thermoplastic resin fibers may be curved and extended while gradually changing their position, or both may be arranged at random. That is, it is only necessary that hybrid resin fibers including at least two kinds of thermoplastic resin fibers exist around the long fibers.
- the arrangement form of at least two kinds of thermoplastic resin fibers with respect to these long fibers can be realized by various methods, but it is effective to use the “braid technology” described below for hybridization. .
- the braid technique is known as a traditional Japanese craft, and is a technique for creating a strong and beautiful knitted pattern by knitting a plurality of thin threads (braids) together.
- a braid is formed in which at least two types of thermoplastic resin fibers serving as braids are arranged around a reinforcing fiber serving as a central thread. Specifically, at least two types of thermoplastic resin fibers are knitted together at a predetermined angle with respect to the longitudinal direction of the reinforcing fibers to form a braid in which at least two types of resin fibers are assembled around the reinforcing fibers.
- FIG. 1A is a schematic view showing an example of an assembly making machine 100 for producing a reinforced fiber / resin fiber composite 50 of the present invention
- FIG. 1B is an external view of the reinforced fiber / resin fiber composite 50.
- the assembly making machine 100 has a center yarn (reinforcing fiber) with respect to a center yarn (reinforcing fiber) 40 serving as a core of the assembly (reinforcing fiber / resin fiber composite 50).
- the central yarn supplying unit 10 for supplying 15 and the braided yarn supplying unit 20 for supplying the braided yarn (resin fiber) 25 are provided. Prior to formation of the braid, the braid supply unit 20 is on standby around the central yarn supply unit 10 for preparation.
- the central yarn supply unit 10 and the braid supply unit 20 are provided as a set.
- one central yarn supply unit 10 and one braid supply unit 20 are set, but a plurality of braid supply units 20 are provided for one central yarn supply unit 10. It is also possible to make a set.
- the number of braid supply units 20 can be appropriately set according to the structure of the reinforcing fiber / resin fiber composite 50 to be designed.
- the central yarn supply unit 10 is connected to a roving (not shown) around which the reinforcing fiber is wound, and discharges the reinforcing fiber unwound from the roving as a central yarn 15 from the tip portion 11.
- the braid supply unit 20 includes a spindle 21 around which the braid 25 is wound, and a rewind bar 22 through which the braid 25 drawn from the spindle 21 passes.
- the braid supply unit 20 revolves around the central yarn supply unit 10 forming a set. At this time, the relative position of the spindle 21 and the rewind bar 22 changes as viewed from above. Thereby, the braided yarn 25 wound around the spindle 21 is continuously released from the spindle 21 through the rewind bar 22.
- the dissociated braids 25 are collected so as to surround the periphery of the central yarn 15, and the central yarn supplying unit 10 and the braided yarn supplying unit 20 move on the assembling machine track 30 so that the longitudinal direction of the central yarn 15 is reached.
- the reinforcing fiber / resin fiber composite 50 (this) as a braid shown in FIG. 1 (b) in which the braid 25 is assembled with the central yarn 15 at the assembly angle ⁇ around the central yarn 40.
- hybridized fiber composites are sometimes referred to as “hybridized fiber composites”.
- the finished reinforcing fiber / resin fiber composite 50 is subjected to thermoforming as it is or in a desired shape to obtain a target long fiber reinforced thermoplastic resin structure. Melting of resin fibers during thermoforming is a kind of so-called in-situ polymer blend and can be easily performed.
- the arrangement of braiding yarns (thermoplastic resin fibers) 25 can be realized in various patterns by devising the way of assembling the braiding yarn 25 with respect to the central yarn 15. Therefore, if the braid technology is applied to the reinforced fiber / resin fiber composite 50 of the present invention, the blending ratio of the reinforced fiber and the thermoplastic resin and the composition ratio of the thermoplastic resin after heat melting can be freely set according to how the yarns are assembled. Can be controlled. As a result, it is possible to manufacture the finished long fiber reinforced thermoplastic resin structure into a form according to the intended use (made to order). In addition, if the braid technique is used, the fiber is not defibrated, and therefore the fiber is not damaged.
- the braid technology when assembling a plurality of braids, it is possible to control the arrangement of the braids and the tension acting on the braids one by one. For this reason, when it is necessary to precisely control the structure and composition of the long-fiber reinforced thermoplastic resin structure as a finished product, it is particularly effective to use the braid technology. Therefore, if the braid technology is used, the physical properties of each resin fiber can be imparted to the long fiber reinforced thermoplastic resin structure after thermoforming in a desired state.
- Examples relating to the reinforcing fiber / resin fiber composite (hybridized fiber composite) of the present invention manufactured using the braided technology described above will be described.
- carbon fibers are used as long fibers that are reinforcing fibers
- polypropylene (PP) fibers are used as thermoplastic resin fibers
- acid-modified polypropylene (MAPP) fibers obtained by acid-modifying PP fibers with maleic acid are used.
- PP fibers are excellent in resin impregnation properties, but interface characteristics (for example, interface shear strength) are slightly inferior.
- MAPP fiber is slightly inferior in resin impregnation, but has excellent interface characteristics. Therefore, using braid technology, PP fiber and MAPP fiber are assembled on the surface of carbon fiber and hybridized, so that the impregnation characteristics of the thermoplastic resin into the carbon fiber and the interface characteristics between the carbon fiber and the thermoplastic resin I tried to make it compatible.
- FIG. 2 is a schematic cross-sectional view of a reinforcing fiber / resin fiber composite 50 for explaining how to assemble the PP fiber 25a and the MAPP fiber 25b (braided yarn 25) with respect to the carbon fiber 15a (central yarn 15).
- a carbon fiber / an intermediate material of the long fiber reinforced thermoplastic resin structure A PP fiber / MAPP fiber composite (hybridized fiber composite) was obtained.
- the resin fibers were assembled in two ways as shown in FIGS. 2 (a) and 2 (b).
- FIG. 3 shows an appearance photograph and a structural diagram of a carbon fiber / resin fiber composite of this example in which two types of thermoplastic resin fibers are assembled with respect to carbon fibers.
- thermoforming is performed using a carbon fiber / resin fiber composite having a two-layer arrangement and an alternating arrangement, and a test piece of a long fiber (carbon fiber) reinforced thermoplastic resin structure (hybridized structure) is prepared. Obtained.
- the thermoforming conditions for each test piece were a molding temperature of 200 ° C., a molding pressure of 10 MPa, a molding time of 5 minutes, 10 minutes, 20 minutes, and 40 minutes.
- the cross section of each test piece was observed, and the impregnation state (non-impregnation rate) of the thermoplastic resin with respect to the carbon fiber was evaluated.
- FIG. 4 is a cross-sectional photograph of the test piece showing the change in the impregnation state depending on the molding time for the two-layer arrangement and the alternate arrangement.
- the numerical value described in the right corner of each photograph is the unimpregnated rate in the carbon fiber.
- the non-impregnation rate is determined by the following procedure.
- FIG. 5 is an example of image data for obtaining the unimpregnated ratio in the carbon fiber, and shows (a) a cross section of the test piece before image processing and (b) a cross section after image processing.
- the cross-sectional image (a) of the carbon fiber (fiber bundle) is binarized with a predetermined threshold value by image processing to obtain a cross-sectional image (b) in which the white region is the impregnated region S1 and the black region is the non-impregnated region S2.
- the non-impregnation rate (%) is obtained from the following equation (1).
- Non-impregnation rate (%) S2 / (S1 + S2) (1)
- FIG. 6 is a graph in which the unimpregnated rate of each test piece in the two-layer arrangement and the alternate arrangement is plotted with respect to the molding time. From FIG. 6, in any of the two-layer arrangement and the alternate arrangement, the unimpregnated ratio of the thermoplastic resin to the carbon fibers gradually decreased with the lapse of the molding time. That is, it was confirmed that the thermoplastic resin was sufficiently impregnated into the carbon fiber as the molding time passed. Further, in comparison between the two-layer arrangement and the alternate arrangement, it has been found that the two-layer arrangement can provide a material having better impregnation characteristics than the alternate arrangement.
- a plate-like body having a length of 50 mm, a width of 20 mm, and a thickness of 2 mm was produced by thermoforming.
- a two-layered carbon fiber / resin fiber composite shown in FIG. 2 and a molded body obtained from the alternately arranged carbon fiber / resin fiber composite were prepared.
- a molded product obtained from a carbon fiber / PP fiber composite and a carbon fiber / MAPP fiber composite was also prepared.
- the thermoforming conditions for each test piece were a molding temperature of 200 ° C., a molding pressure of 10 MPa, a molding time of 5 minutes, 10 minutes, 20 minutes, and 40 minutes.
- FIG. 7 is a graph of measurement data (load-deflection curve) by a three-point bending test of each test piece. Based on the measurement data, the bending elastic modulus E (MPa) and bending stress ⁇ (MPa) of each test piece were estimated using the following formulas (2) and (3). The maximum value of the bending stress ⁇ is defined as the bending strength. In addition, these calculations were performed by the method based on JISK7017.
- (Hybridized structure) has greatly improved elastic modulus and strength than long fiber reinforced thermoplastic resin structure (non-hybridized structure) molded from carbon fiber / PP fiber composite (Test No. 3) was confirmed.
- the two-layer carbon fiber / resin fiber composite (Test No. 1) showed the same elastic modulus and strength as the carbon fiber / MAPP fiber composite (Test No. 4).
- the carbon fiber / resin fiber composite if the resin fiber is formed by using a hybrid of PP fiber and MAPP fiber yarn, the carbon fiber / A high-performance long fiber reinforced thermoplastic resin structure having sufficient strength in the long fiber direction (longitudinal direction) can be obtained while realizing high interface characteristics similar to those of a MAPP fiber composite.
- the at least two types of resin fibers constituting the carbon fiber / resin fiber composite are made of various combinations of materials in addition to the PP fibers and MAPP fibers described in the above embodiment. It is possible to select.
- the resin fiber composites include the following combinations of resin fibers, and the properties that can be complemented (compatibility) when each combination is selected are listed.
- Polylactic acid (PLA) fiber / polyoxymethylene (POM) fiber interfacial characteristics and impregnation / toughness
- polyamide (PA) fiber / polyoxymethylene (POM) fiber interfacial adhesiveness / abrasion resistance and slidability
- the hybridized fiber composite produced by the braid technology can be made into various structures according to the target long fiber reinforced thermoplastic resin structure.
- braids are square braids, flat struts, round struts, and the like, which are traditionally assembled, and hybrid fiber composites can be constructed based on these braids.
- a reinforcing fiber / resin fiber composite as an intermediate material is produced as a ribbon-like flat string, and this is rolled up and formed into a ring shape. Thereby, a lightweight and high-strength hollow pillar can be manufactured.
- reinforcing fibers are used for the center yarn 40 and the central yarn 15 and resin fibers are used for the braid 25,
- the type of fibers to be combined with the center yarn 40, the center yarn 15, and the braid 25 is not particularly limited, and can be appropriately determined according to the reinforcing fiber / resin fiber composite to be produced.
- the reinforcing fiber / resin fiber composite of the present invention is an intermediate material for a long fiber reinforced thermoplastic resin structure, and can be suitably used in the fields of automobiles, ships, aircraft, and the like.
- Central thread supply section 11 Tip section 15 Central thread (reinforced fiber) 15a Carbon fiber 20 Braid supply section 21 Spindle 22 Rewind bar 25 Braid (resin fiber) 25a PP fiber 25b MAPP fiber 40 Center yarn (reinforced fiber) 50 Reinforcing fiber / resin fiber composite 100 Assembly machine
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Abstract
Description
長繊維強化熱可塑性樹脂構造物の中間材料となる強化繊維/樹脂繊維複合体であって、
前記強化繊維は長手方向に延在する長繊維であり、
前記樹脂繊維は少なくとも2種の熱可塑性樹脂繊維を有しており、
前記強化繊維を包囲するように、前記少なくとも2種の熱可塑性樹脂繊維を前記強化繊維の周囲に配置してあることにある。
この点、本構成の強化繊維/樹脂繊維複合体によれば、強化繊維として長手方向に延在する長繊維を使用するとともに、樹脂繊維として少なくとも2種の熱可塑性樹脂繊維を使用する場合において、強化繊維を包囲するように、少なくとも2種の熱可塑性樹脂繊維を強化繊維の周囲に配置した形態としている。つまり、長繊維の周囲に、少なくとも2種の熱可塑性樹脂繊維を含むハイブリッド化された樹脂繊維が存在している。このような形態の強化繊維/樹脂繊維複合体を用いて熱成形を行う場合、少なくとも2種の熱可塑性樹脂繊維として適宜選択を行えば、例えば、強化繊維を包囲する熱可塑性樹脂繊維が溶融したときに強化繊維の内部まで熱可塑性樹脂を確実に含浸させつつ、強化繊維と熱可塑性樹脂との界面特性を向上させることができる。その結果、両者の界面剥離を防止することができる。なお、この熱成形時における熱可塑性樹脂繊維の溶融は、いわゆるIn-situポリマーブレンドの一種であり、簡単に行うことができる。
前記少なくとも2種の熱可塑性樹脂繊維を、前記長繊維の長手方向に対して所定角度で相互に組み合わした組紐の状態で、前記強化繊維の周囲に配置してあることが好ましい。
この点、本構成の強化繊維/樹脂繊維複合体によれば、少なくとも2種の熱可塑性樹脂繊維を、長繊維(強化繊維)の長手方向に対して所定角度で相互に組み合わした組紐の状態で、強化繊維の周囲に配置した形態としている。すなわち、伝統工芸として知られている「組紐技術」を利用して、強化繊維の周囲に少なくとも2種の熱可塑性樹脂繊維を組んだものとしている。組紐技術においては、紐(繊維)の組み方を工夫することにより、紐(繊維)の配置形態を様々なパターンで実現することができる。従って、組紐技術を強化繊維/樹脂繊維複合体に適用すれば、強化繊維と熱可塑性樹脂との配合割合や、少なくとも2種の熱可塑性樹脂の組成比を、糸の組み方によって自在にコントロールすることが可能となる。しかも、組紐技術を利用すれば、紐(繊維)を解繊することがないので、繊維が損傷を受けるおそれもない。
また、組紐技術においては、複数の紐(繊維)を組み上げる際に、紐(繊維)の配置や紐(繊維)に作用するテンションを一本ずつコントロールすることが可能となる。このため、本構成の強化繊維/樹脂繊維複合体は、完成品である長繊維強化熱可塑性樹脂構造物の構造及び組成を精密に制御する必要がある場合において、特に有効である。従って、組紐技術を用いれば、夫々の樹脂繊維が有する物性を熱成形後の長繊維強化熱可塑性樹脂構造物に所望の状態で付与することが可能となる。
前記少なくとも2種の熱可塑性樹脂繊維は、熱成形後に各繊維の物性が相互に補完されるように選択されることが好ましい。
前記少なくとも2種の熱可塑性樹脂繊維は、ポリ乳酸(PLA)繊維、ポリアミド(PA)繊維、ポリカーボネート(PC)繊維、ポリオキシメチレン(POM)繊維、ポリプロピレン(PP)繊維、酸変性ポリプロピレン(MAPP)繊維、ポリエチレン(PE)繊維、ポリフェニレンサルファイド(PPS)繊維、ポリエーテル・エーテル・ケトン(PEEK)繊維、及びポリエーテル・ケトン・ケトン(PEKK)繊維からなる群から選択されることが好ましい。
前記少なくとも2種の熱可塑性樹脂繊維は、ポリプロピレン(PP)繊維、及び酸変性ポリプロピレン(MAPP)繊維であることが好ましい。
前記少なくとも2種の熱可塑性樹脂繊維は、ポリ乳酸(PLA)繊維、及びポリオキシメチレン(POM)繊維であることが好ましい。
長繊維強化熱可塑性樹脂構造物の中間材料となる強化繊維/樹脂繊維複合体の製造方法であって、
前記強化繊維は長手方向に延在する長繊維であり、
前記樹脂繊維は少なくとも2種の熱可塑性樹脂繊維を有しており、
前記少なくとも2種の熱可塑性樹脂繊維を前記強化繊維の周囲にスタンバイする準備工程と、
前記強化繊維を包囲するように、前記少なくとも2種の熱可塑性樹脂繊維を前記長手方向に対して所定角度で連続的に相互に組み合わせる組紐工程と、
を包含することにある。
すなわち、長繊維の周囲に、少なくとも2種の熱可塑性樹脂繊維を含むハイブリッド化された樹脂繊維が存在している強化繊維/樹脂繊維複合体を用いて熱成形を行う場合、少なくとも2種の熱可塑性樹脂繊維として適宜選択を行えば、例えば、強化繊維を包囲する熱可塑性樹脂繊維が溶融したときに強化繊維の内部まで熱可塑性樹脂を確実に含浸させつつ、強化繊維と熱可塑性樹脂との界面特性を向上させることができる。その結果、両者の界面剥離を防止することができる。なお、この熱成形時における熱可塑性樹脂繊維の溶融は、いわゆるIn-situポリマーブレンドの一種であり、簡単に行うことができる。
さらに、本構成の強化繊維/樹脂繊維複合体の製造方法は、伝統工芸として知られている「組紐技術」を利用したものである。組紐技術においては、紐(繊維)の組み方を工夫することにより、紐(繊維)の配置形態を様々なパターンで実現することができる。従って、組紐技術を強化繊維/樹脂繊維複合体の製造に適用すれば、強化繊維と熱可塑性樹脂との配合割合や、少なくとも2種の熱可塑性樹脂の組成比を、糸の組み方によって自在にコントロールすることが可能となる。しかも、組紐技術を利用すれば、紐(繊維)を解繊することがないので、繊維が損傷を受けるおそれもない。
また、組紐技術においては、複数の紐(繊維)を組み上げる際に、紐(繊維)の配置や紐(繊維)に作用するテンションを一本ずつコントロールすることが可能となる。このため、本構成の強化繊維/樹脂繊維複合体の製造方法は、完成品である長繊維強化熱可塑性樹脂構造物の構造及び組成を精密に制御する必要がある場合において、特に有効である。従って、組紐技術を用いれば、夫々の樹脂繊維が有する物性を熱成形後の長繊維強化熱可塑性樹脂構造物に所望の状態で付与することが可能となる。
長繊維強化熱可塑性樹脂構造物の中間材料となる本発明の強化繊維/樹脂繊維複合体は、長繊維と熱可塑性樹脂繊維とを含む複合物又は混合物として構成される。長繊維は、モノフィラメントの集合体であるマルチフィラメントで構成され、細長のマルチフィラメントが長手方向に延在して糸条をなしている。長繊維には、強化繊維(例えば、炭素繊維、ガラス繊維、アラミド繊維等)を用いることができる。
組紐技術は、日本の伝統工芸として知られており、複数の細い糸(組糸)を相互に編んで織り上げることにより、強靭で且つ美しい編模様を備えた紐を作り上げる技術である。本発明では、中央糸となる強化繊維の周囲に、組糸となる少なくとも2種の熱可塑性樹脂繊維を配置した組物を形成する。具体的には、強化繊維の長手方向に対して少なくとも2種の熱可塑性樹脂繊維を所定角度で相互に編み上げることより、強化繊維の周囲に少なくとも2種の樹脂繊維が組まれた組紐が形成される。
図2は、炭素繊維15a(中央糸15)に対するPP繊維25a及びMAPP繊維25b(組糸25)の組み方を説明するための強化繊維/樹脂繊維複合体50の断面模式図である。本実施例では、1本の炭素繊維15aに対して、16本のPP繊維25a、及び16本のMAPP繊維25bを組み上げることにより、長繊維強化熱可塑性樹脂構造物の中間材料となる炭素繊維/PP繊維/MAPP繊維複合体(ハイブリッド化繊維複合体)を得た。樹脂繊維の組み方は、図2(a)及び(b)に示す2通りを実行した。(a)は、一段目として炭素繊維15aの表面を包囲するようにPP繊維25aのみを組み上げ、次いで、二段目として一段目の上にMAPP繊維25bのみを組み上げたものである。(a)の組み方を「二層配置」と称する。(b)は、一段目として炭素繊維15aの表面を包囲するようにPP繊維25aとMAPP繊維25bとを交互に組み上げ、次いで、二段目として一段目と同様にPP繊維25aとMAPP繊維25bとを交互に組み上げたものである。(b)の組み方を「交互配置」と称する。図3に、炭素繊維に対して2種の熱可塑性樹脂繊維が組み上げられた本実施例の炭素繊維/樹脂繊維複合体の外観写真、及び構造図を示す。
炭素繊維/樹脂繊維複合体(ハイブリッド化繊維複合体)を熱成形して得られる長繊維強化熱可塑性樹脂構造物(これを「ハイブリッド化構造物」と称する場合がある)の含浸特性について、顕微鏡による断面観察から評価した。
未含浸率(%) = S2/(S1+S2) ・・・ (1)
炭素繊維/樹脂繊維複合体(ハイブリッド化繊維複合体)を熱成形して得られる長繊維強化熱可塑性樹脂構造物(ハイブリッド化構造物)について、曲げ試験機を用いた三点曲げ試験を実施し、界面特性を評価した。三点曲げ試験により長繊維強化熱可塑性樹脂構造物の長手方向における力学的特性を測定し、弾性率及び強度の値が大きいほど、界面特性が良好であることが間接的に推定できる。
E=L3/(4bh3)・(ΔF/ΔS) ・・・ (2)
σ=3FL/(2bh2) ・・・ (3)
L :支点間距離(mm)
b :試験片の幅(mm)
h :試験片の厚さ(mm)
F :荷重(N)
ΔS:曲げ歪みε’=0.0005及びε”=0.0025に対応する曲げ撓みS’及びS”間の撓みの差(mm)
ΔF:S’及びS”における夫々の荷重F’とF”との差(N)
試験結果を以下の表1に示す。
(1)炭素繊維/樹脂繊維複合体(ハイブリッド化繊維複合体)を構成する少なくとも2種の樹脂繊維は、上記実施形態で説明したPP繊維、及びMAPP繊維の他にも種々の組み合わせの材料を選択することが可能である。例えば、樹脂繊維複合体として、以下の樹脂繊維の組合せが挙げられ、各組合せを選択した場合の補完可能(両立可能)な物性について列挙する。
〔1〕ポリ乳酸(PLA)繊維/ポリオキシメチレン(POM)繊維:界面特性及び含浸性/靭性
〔2〕ポリプロピレン(PP)繊維/ポリアミド(PA)繊維(ナイロン繊維):含浸性/界面接着性、低コスト/界面接着性
〔3〕ポリアミド(PA)繊維/ポリオキシメチレン(POM)繊維:界面接着性/耐摩耗性及び摺動性
〔4〕ポリプロピレン(PP)繊維/ポリオキシメチレン(POM)繊維:含浸性/耐摩耗性及び摺動性
〔5〕ポリアミド(PA)繊維/ポリフェニレンサルファイド(PPS)繊維:界面接着性/耐熱性、界面接着性/含浸性
〔6〕ポリプロピレン(PP)繊維/ポリカーボネート(PC)繊維:含浸性/耐衝撃性
〔7〕ポリアミド(PA)繊維/ポリカーボネート(PC)繊維:界面接着性/耐衝撃性
その他にも樹脂繊維複合体を構成する少なくとも2種の樹脂繊維として、例えば、ポリエチレン(PE)繊維、ポリエーテル・エーテル・ケトン(PEEK)繊維、ポリエーテル・ケトン・ケトン(PEKK)繊維等の熱可塑性樹脂繊維が挙げられる。また、補完可能な熱可塑性樹脂繊維の物性としては、上述した物性の他に、吸水性、耐疲労性、耐薬品性、耐溶剤性、難燃性、電気的特性、耐寒性、耐候性等が挙げられる。
11 先端部
15 中央糸(強化繊維)
15a 炭素繊維
20 組糸供給部
21 スピンドル
22 巻戻しバー
25 組糸(樹脂繊維)
25a PP繊維
25b MAPP繊維
40 中心糸(強化繊維)
50 強化繊維/樹脂繊維複合体
100 組物作製機
Claims (7)
- 長繊維強化熱可塑性樹脂構造物の中間材料となる強化繊維/樹脂繊維複合体であって、
前記強化繊維は長手方向に延在する長繊維であり、
前記樹脂繊維は少なくとも2種の熱可塑性樹脂繊維を有しており、
前記強化繊維を包囲するように、前記少なくとも2種の熱可塑性樹脂繊維を前記強化繊維の周囲に配置してある強化繊維/樹脂繊維複合体。 - 前記少なくとも2種の熱可塑性樹脂繊維を、前記長繊維の長手方向に対して所定角度で相互に組み合わした組紐の状態で、前記強化繊維の周囲に配置してある請求項1に記載の強化繊維/樹脂繊維複合体。
- 前記少なくとも2種の熱可塑性樹脂繊維は、熱成形後に各繊維の物性が相互に補完されるように選択される請求項1又は2に記載の強化繊維/樹脂繊維複合体。
- 前記少なくとも2種の熱可塑性樹脂繊維は、ポリ乳酸(PLA)繊維、ポリアミド(PA)繊維、ポリカーボネート(PC)繊維、ポリオキシメチレン(POM)繊維、ポリプロピレン(PP)繊維、酸変性ポリプロピレン(MAPP)繊維、ポリエチレン(PE)繊維、ポリフェニレンサルファイド(PPS)繊維、ポリエーテル・エーテル・ケトン(PEEK)繊維、及びポリエーテル・ケトン・ケトン(PEKK)繊維からなる群から選択される請求項1~3の何れか一項に記載の強化繊維/樹脂繊維複合体。
- 前記少なくとも2種の熱可塑性樹脂繊維は、ポリプロピレン(PP)繊維、及び酸変性ポリプロピレン(MAPP)繊維である請求項1~3の何れか一項に記載の強化繊維/樹脂繊維複合体。
- 前記少なくとも2種の熱可塑性樹脂繊維は、ポリ乳酸(PLA)繊維、及びポリオキシメチレン(POM)繊維である請求項1~3の何れか一項に記載の強化繊維/樹脂繊維複合体。
- 長繊維強化熱可塑性樹脂構造物の中間材料となる強化繊維/樹脂繊維複合体の製造方法であって、
前記強化繊維は長手方向に延在する長繊維であり、
前記樹脂繊維は少なくとも2種の熱可塑性樹脂繊維を有しており、
前記少なくとも2種の熱可塑性樹脂繊維を前記強化繊維の周囲にスタンバイする準備工程と、
前記強化繊維を包囲するように、前記少なくとも2種の熱可塑性樹脂繊維を前記長手方向に対して所定角度で連続的に相互に組み合わせる組紐工程と、
を包含する強化繊維/樹脂繊維複合体の製造方法。
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WO2014061384A1 (ja) * | 2012-10-17 | 2014-04-24 | 国立大学法人岐阜大学 | 連続繊維強化熱可塑性樹脂複合材料製造用の強化繊維/樹脂繊維複合体、およびその製造方法 |
JP2019523161A (ja) * | 2016-07-08 | 2019-08-22 | ショマラ・テキスタイルズ・インダストリーズChomarat Textiles Industries | 熱可塑性樹脂含浸法での使用に適したテキスタイル強化材 |
WO2019172208A1 (ja) | 2018-03-05 | 2019-09-12 | 旭化成株式会社 | 熱可塑性樹脂コーティング強化繊維複合糸、該複合糸の製造方法、連続繊維強化樹脂成形体、複合材料成形体の製造方法 |
JP2019167648A (ja) * | 2018-03-23 | 2019-10-03 | 三菱ケミカル株式会社 | 一方向性補強繊維シートおよび組紐 |
JP7106918B2 (ja) | 2018-03-23 | 2022-07-27 | 三菱ケミカル株式会社 | 一方向性補強繊維シートおよび組紐 |
Also Published As
Publication number | Publication date |
---|---|
EP2759387B1 (en) | 2017-09-13 |
EP2759387A4 (en) | 2015-04-15 |
EP2759387A1 (en) | 2014-07-30 |
US20140230634A1 (en) | 2014-08-21 |
JPWO2013042763A1 (ja) | 2015-03-26 |
JP6014878B2 (ja) | 2016-10-26 |
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