WO2013046452A1 - 繊維強化樹脂複合材及びその製造方法 - Google Patents
繊維強化樹脂複合材及びその製造方法 Download PDFInfo
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- WO2013046452A1 WO2013046452A1 PCT/JP2011/072628 JP2011072628W WO2013046452A1 WO 2013046452 A1 WO2013046452 A1 WO 2013046452A1 JP 2011072628 W JP2011072628 W JP 2011072628W WO 2013046452 A1 WO2013046452 A1 WO 2013046452A1
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- WIPO (PCT)
- Prior art keywords
- resin
- fiber
- shape portion
- composite material
- benzoxazine
- Prior art date
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Definitions
- the present invention relates to a fiber reinforced resin composite material and a method for producing the same, and more particularly to a fiber reinforced resin composite material used as a structural member for aircraft, automobiles, ships, etc. and a method for producing the same.
- fiber reinforced resin composites have been widely used as structural members for aircraft, automobiles, ships, and the like.
- FRP Fiber Reinforced Plastics
- a fiber reinforced resin composite material as a simple shape portion, an outer plate portion obtained by laminating a sheet-like prepreg material impregnated with a carbon fiber resin, and a complicated shape portion as an inner portion of the outer plate portion.
- a reinforcing part such as a girder made of fiber reinforced resin, a small bone, and a longitudinal member provided integrally and an auxiliary member such as a bracket are provided.
- VaRTM Vacuum-assisted Resin Transfer Molding
- the joint surface between the simple shape portion and the complex shape portion becomes an interface. If the interface exists, the strength of the fiber-reinforced resin composite material may be reduced due to the interface. For this reason, the subject of this invention is suppressing the strength fall resulting from the interface of a simple shape part and a complicated shape part.
- the fiber reinforced resin composite material according to the invention of claim 1 is: A simple shape portion composed of at least one sheet-like prepreg material in which a reinforcing fiber is impregnated with a resin; It is formed integrally with the simple shape part, and comprises a complex shape part formed by impregnating a reinforcing fiber with resin,
- the resin used for the prepreg material and the resin used for the complicated shape portion are the same component.
- the invention according to claim 2 is the fiber reinforced resin composite material according to claim 1,
- the resin used for the prepreg material and the resin used for the complicated shape portion are benzoxazine resin compositions.
- the invention according to claim 3 is the fiber reinforced resin composite material according to claim 2,
- the benzoxazine resin composition is It contains a compound having a benzoxazine ring represented by formula (1) in the molecule, an epoxy resin, a curing agent, and a toughness improver.
- R 1 represents a chain alkyl group having 1 to 12 carbon atoms, a cyclic alkyl group having 3 to 8 carbon atoms, a phenyl group, a chain alkyl group having 1 to 12 carbon atoms, or a phenyl group substituted with halogen.
- a hydrogen atom is bonded to at least one of the ortho-position and para-position of the carbon atom to which the oxygen atom of the aromatic ring is bonded.
- the resin used for the prepreg material and the resin used for the complicated shape portion are the same component.
- Invention of Claim 5 is a manufacturing method of the fiber reinforced resin composite material of Claim 4,
- the resin used for the prepreg material and the resin used for the complicated shape portion are benzoxazine resin compositions.
- the benzoxazine resin composition is It contains a compound having a benzoxazine ring represented by formula (1) in the molecule, an epoxy resin, a curing agent, and a toughness improver.
- R 1 represents a chain alkyl group having 1 to 12 carbon atoms, a cyclic alkyl group having 3 to 8 carbon atoms, a phenyl group, a chain alkyl group having 1 to 12 carbon atoms, or a phenyl group substituted with halogen.
- a hydrogen atom is bonded to at least one of the ortho-position and para-position of the carbon atom to which the oxygen atom of the aromatic ring is bonded.
- the resin used for the existing prepreg and the resin used for the complex shape part (RTM resin) have different characteristics required for each material, the vacuum resin impregnation method as in the prior art. Then, when the resin of the component from which a simple shape part and a complicated shape part differ is used, it paid attention to that both joint surfaces will become an interface. Therefore, the present inventors have found that if a simple shape portion and a complex shape portion are formed of the same component resin, the strength reduction can be suppressed without integration of the joint surface between the two after integration. That is, according to the present invention, it is possible to suppress a decrease in strength due to the interface between the simple shape portion and the complex shape portion.
- FIG. 1 is a schematic perspective view showing a schematic configuration of a fiber-reinforced resin composite material according to the present embodiment.
- the fiber reinforced resin composite material 1 includes an outer plate portion 2 as a simple shape portion and a reinforcing portion 3 as a complicated shape portion formed integrally with the outer plate portion 2. Is provided.
- the outer plate portion 2 is formed of a plurality of laminated sheet-like prepreg materials 4.
- the prepreg material 4 is formed by impregnating a reinforcing fiber with a resin.
- the reinforcing portion 3 includes a pedestal portion 31 fixed to the outer plate portion 2 and a rib 32 erected from the center of the pedestal portion 31.
- the reinforcing portion 3 is also formed by impregnating a reinforcing fiber with a resin.
- the resin used in the prepreg material 4 forming the outer plate portion 2 and the resin used in the reinforcing portion 3 are the same component.
- This resin is a benzoxazine resin composition
- A a compound having a benzoxazine ring represented by the formula (1) in the molecule
- B an epoxy resin
- C a curing agent
- D Toughness improver
- the compound (A) is a benzoxazine resin represented by the above formula (1).
- R 1 is substituted with a chain alkyl group having 1 to 12 carbon atoms, a cyclic alkyl group having 3 to 8 carbon atoms, a phenyl group, or a chain alkyl group having 1 to 12 carbon atoms or a halogen.
- Examples of the chain alkyl group having 1 to 12 carbon atoms include a methyl group, an ethyl group, a propyl group, an isopropyl group, an n-butyl group, an isobutyl group, and a t-butyl group.
- Examples of the cyclic alkyl group having 3 to 8 carbon atoms include a cyclopentyl group and a cyclohexyl group.
- Examples of the phenyl group substituted with a linear alkyl group having 1 to 12 carbon atoms or halogen include, for example, a phenyl group, an o-methylphenyl group, an m-methylphenyl group, a p-methylphenyl group, an o-ethylphenyl group, Examples include m-ethylphenyl group, p-ethylphenyl group, ot-butylphenyl group, mt-butylphenyl group, pt-butylphenyl group, o-chlorophenyl group, and o-bromophenyl group.
- R 1 is preferably a methyl group, an ethyl group, a propyl group, a phenyl group, or an o
- benzoxazine resin as the compound (A) examples include a monomer represented by the following formula, an oligomer obtained by polymerizing several monomers of the monomer, a compound having a benzoxazine ring having a structure different from these monomers, and the monomers.
- a reaction product with at least one kind is preferred.
- the compound is excellent in flame retardancy because the benzoxazine ring undergoes ring-opening polymerization to form the same skeleton as the phenol resin.
- excellent mechanical properties such as low water absorption and high elastic modulus can be obtained from the dense structure.
- the epoxy resin is a component that controls the viscosity of the composition and increases the curability of the composition.
- the epoxy resin which uses compounds, such as amines, phenols, carboxylic acid, intramolecular unsaturated carbon, as a precursor, for example is preferable.
- epoxy resins having amines as precursors include tetraglycidyldiaminodiphenylmethane, glycidyl compounds of xylenediamine, triglycidylaminophenol, and glycidylanilines, their respective positional isomers, and substitution with alkyl groups or halogens. It is done.
- the complex viscoelastic modulus ⁇ * at 25 ° C. obtained by a dynamic viscoelasticity measuring device described later is described as the viscosity.
- triglycidylaminophenol Commercially available products of triglycidylaminophenol include, for example, “jER” 630 (viscosity: 750 mPa ⁇ s) (manufactured by Mitsubishi Chemical Corporation), “Araldite” MY0500 (viscosity: 3500 mPa ⁇ s), MY0510 (viscosity: 600 mPa ⁇ s). s) (manufactured by Huntsman Advanced Materials), ELM100 (viscosity: 16000 mPa ⁇ s) (manufactured by Sumitomo Chemical).
- Examples of commercially available glycidylanilines include GAN (viscosity: 120 mPa ⁇ s) and GOT (viscosity: 60 mPa ⁇ s) (manufactured by Nippon Kayaku Co., Ltd.).
- Examples of the glycidyl ether type epoxy resin having phenol as a precursor include, for example, bisphenol A type epoxy resin, bisphenol F type epoxy resin, bisphenol S type epoxy resin, epoxy resin having a biphenyl skeleton, phenol novolak type epoxy resin, cresol novolak type Epoxy resin, resorcinol type epoxy resin, epoxy resin having naphthalene skeleton, trisphenylmethane type epoxy resin, phenol aralkyl type epoxy resin, dicyclopentadiene type epoxy resin, diphenylfluorene type epoxy resin and various isomers and alkyl groups thereof, Examples include halogen substitution products. Moreover, an epoxy resin obtained by modifying an epoxy resin having a phenol precursor with urethane or isocyanate is also included in this type.
- liquid bisphenol A type epoxy resins examples include “jER” 825 (viscosity: 5000 mPa ⁇ s), “jER” 826 (viscosity: 8000 mPa ⁇ s), and “jER” 827 (viscosity: 10,000 mPa ⁇ s).
- JER 828 viscosity: 13000 mPa ⁇ s) (above, manufactured by Mitsubishi Chemical Corporation), “Epiclon” (registered trademark, the same applies hereinafter) 850 (viscosity: 13000 mPa ⁇ s) (made by DIC Corporation), “Epototo” (registered trademark, the same applies hereinafter) YD-128 (viscosity: 13000 mPa ⁇ s) (manufactured by Nippon Steel Chemical Co., Ltd.), DER-331 (viscosity: 13000 mPa ⁇ s), DER-332 (viscosity: 5000 mPa ⁇ s) s) (manufactured by Dow Chemical Company).
- Examples of commercially available solid or semi-solid bisphenol A type epoxy resins include “jER” 834, “jER” 1001, “jER” 1002, “jER” 1003, “jER” 1004, “jER” 1004AF, and “jER”. "1007" and “jER” 1009 (above, manufactured by Mitsubishi Chemical Corporation).
- liquid bisphenol F-type epoxy resins examples include “jER” 806 (viscosity: 2000 mPa ⁇ s), “jER” 807 (viscosity: 3500 mPa ⁇ s), and “jER” 1750 (viscosity: 1300 mPa ⁇ s).
- Examples of commercially available solid bisphenol F type epoxy resins include 4004P, “jER” 4007P, “jER” 4009P (above, manufactured by Mitsubishi Chemical Corporation), “Epototo” YDF2001, “Epototo” YDF2004 (above, new) Manufactured by Nippon Steel Chemical Co., Ltd.).
- Examples of the bisphenol S type epoxy resin include EXA-1515 (manufactured by DIC Corporation).
- Examples of commercially available epoxy resins having a biphenyl skeleton include “jER” YX4000H, “jER” YX4000, “jER” YL6616 (manufactured by Mitsubishi Chemical Corporation), NC-3000 (manufactured by Nippon Kayaku Co., Ltd.). ).
- Examples of commercially available phenol novolac epoxy resins include “jER” 152, “jER” 154 (manufactured by Mitsubishi Chemical Corporation), “Epicron” N-740, “Epicron” N-770, “Epicron”. N-775 (manufactured by DIC Corporation).
- Examples of commercially available cresol novolac type epoxy resins include “Epiclon” N-660, “Epicron” N-665, “Epicron” N-670, “Epicron” N-673, “Epicron” N-695 (above, DIC Corporation), EOCN-1020, EOCN-102S, EOCN-104S (above, Nippon Kayaku Co., Ltd.).
- Examples of commercially available resorcinol-type epoxy resins include “Denacol” (registered trademark, hereinafter the same) EX-201 (viscosity: 250 mPa ⁇ s) (manufactured by Nagase ChemteX Corporation).
- Examples of commercially available epoxy resins having a naphthalene skeleton include “Epiclon” HP4032 (manufactured by DIC Corporation), NC-7000, NC-7300 (manufactured by Nippon Kayaku Co., Ltd.).
- Examples of commercially available trisphenylmethane type epoxy resins include TMH-574 (manufactured by Sumitomo Chemical Co., Ltd.).
- dicyclopentadiene type epoxy resins include, for example, “Epicron” HP7200, “Epicron” HP7200L, “Epicron” HP7200H (above, manufactured by DIC Corporation), “Tactix” (registered trademark) 558 (Huntsman Advanced) -Material Co., Ltd.), XD-1000-1L, XD-1000-2L (Nippon Kayaku Co., Ltd.).
- examples of commercially available urethane and isocyanate-modified epoxy resins include AER4152 (produced by Asahi Kasei E-Materials Co., Ltd.) having an oxazolidone ring.
- Examples of the epoxy resin using carboxylic acid as a precursor include glycidyl compounds of phthalic acid, glycidyl compounds of hexahydrophthalic acid and dimer acid, and various isomers thereof.
- diglycidyl phthalate examples include, for example, “Epomic” (registered trademark, the same applies hereinafter) R508 (viscosity: 4000 mPa ⁇ s) (manufactured by Mitsui Chemicals), “Denacol” EX-721 (viscosity: 980 mPas). S) (manufactured by Nagase ChemteX Corporation).
- hexahydrophthalic acid diglycidyl ester Commercially available products of hexahydrophthalic acid diglycidyl ester include, for example, “Epomic” R540 (viscosity: 350 mPa ⁇ s) (manufactured by Mitsui Chemicals), AK-601 (viscosity: 300 mPa ⁇ s) (Nippon Kayaku Co., Ltd.) Co., Ltd.).
- dimer acid diglycidyl esters include “jER” 871 (viscosity: 650 mPa ⁇ s) (manufactured by Mitsubishi Chemical Corporation), “Epototo” YD-171 (viscosity: 650 mPa ⁇ s) (Nippon Steel). Chemical Co., Ltd.).
- Examples of the epoxy resin having an intramolecular unsaturated carbon as a precursor include an alicyclic epoxy resin.
- an alicyclic epoxy resin for example, “Celoxide” (registered trademark, the same shall apply hereinafter) 2021P (viscosity: 250 mPa ⁇ s) ) (Manufactured by Daicel Chemical Industries, Ltd.), CY179 (viscosity: 400 mPa ⁇ s) (manufactured by Huntsman Advanced Materials), (3 ′, 4′-epoxycyclohexane) octyl 3,4-epoxycyclohexanecarboxylate Examples thereof include “Celoxide” 2081 (viscosity: 100 mPa ⁇ s) (manufactured by Daicel Chemical Industries, Ltd.), 1-methyl-4
- the blending amount of the (B) epoxy resin is preferably 10 to 100 parts by mass and more preferably 10 to 60 parts by mass with respect to 100 parts by mass of the benzoxazine resin of the compound (A).
- it is s or more and 15000 mPa * s or less. When it exceeds 20000 mPa ⁇ s, tack and drape properties may deteriorate.
- an epoxy resin having a high aromatic content is preferable in order to increase flame retardancy.
- an epoxy resin having a biphenyl skeleton, an epoxy resin having a naphthalene skeleton, or a phenol aralkyl type epoxy resin is preferable in order to increase flame retardancy.
- curing agent examples include aromatic amines such as diethyltoluenediamine, metaphenylenediamine, diaminodiphenylmethane, diaminodiphenylsulfone, metaxylenediamine, and various derivatives thereof, and aliphatic amines such as triethylenetetramine and isophoronediamine.
- aromatic amines such as diethyltoluenediamine, metaphenylenediamine, diaminodiphenylmethane, diaminodiphenylsulfone, metaxylenediamine, and various derivatives thereof
- aliphatic amines such as triethylenetetramine and isophoronediamine.
- carboxylic acid anhydrides such as methylhexahydrophthalic anhydride
- the compounding amount of the curing agent is preferably 5 to 30 parts by mass, more preferably 7 to 25 parts by mass with respect to 100 parts by mass of (A) compound + (B) epoxy resin. If it is less than 5 parts by mass, the curing reaction does not proceed, so that the degree of curing of the entire resin composition may be insufficient. When it exceeds 30 mass parts, there exists a possibility that mechanical properties, such as a glass transition temperature of hardened
- the toughness improver there are those that are dispersed in the resin composition as organic fine particles or inorganic fine particles, and those that are dissolved in the resin composition as a liquid resin or resin monomer. However, some of them that are dispersed may be dissolved in the resin composition, and some that may be dissolved may exist as fine particles without being dissolved due to polymerization or other reasons.
- reactive elastomer hiker CTBN modified epoxy resin, hiker CTB modified epoxy resin, urethane modified epoxy resin, nitrile rubber added epoxy resin, crosslinked acrylic rubber fine particle added epoxy resin, silicone modified epoxy resin, thermoplastic elastomer added epoxy resin are used it can.
- the inorganic fine particle filler for example, mica, alumina, talc, finely divided silica, wollastonite, sepiolite, basic magnesium sulfate, calcium carbonate, polytetrafluoroethylene powder, zinc powder, and aluminum powder can be used.
- the organic fine particles for example, thermosetting resin fine particles, thermoplastic resin fine particles, or a mixture thereof can be used.
- thermosetting resin fine particles include epoxy resin fine particles, phenol resin fine particles, melamine resin fine particles, urea resin fine particles, silicone resin fine particles, urethane resin fine particles, or a mixture thereof.
- thermoplastic resin fine particles examples include copolymer polyester resin fine particles, polyimide resin fine particles, polyamide resin fine particles, acrylic fine particles, butadiene-acrylonitrile resin fine particles, styrene fine particles, olefin fine particles, nylon fine particles, butadiene / alkyl methacrylate.
- acrylic fine particles can be preferably used because of their good dispersibility in epoxy resins.
- the acrylic fine particles can be produced by (1) monomer polymerization, (2) polymer chemical treatment, (3) polymer mechanical pulverization, etc., but the method (3) gives a fine product. Therefore, it is not preferable because the shape is irregular.
- the polymerization method include emulsion polymerization, soap-free emulsion polymerization, dispersion polymerization, seed polymerization, suspension polymerization, or a method in which these are used in combination with each other, the particle size is fine, partially crosslinked structure, core / shell structure, Emulsion polymerization and seed polymerization are used in which fine particles having a hollow structure and a polar structure (epoxy group, carboxyl group, hydroxyl group, etc.) are obtained.
- a polar structure epoxy group, carboxyl group, hydroxyl group, etc.
- Partly crosslinked fine particles and core / shell type fine particles obtained by these are preferably used.
- core / shell type fine particles include Staphyloid AC3355 (trade name, manufactured by Ganz Kasei Co., Ltd.), MX120 (trade name, manufactured by Kaneka Corporation), and the like.
- the blending ratio of the toughness improver is preferably 1 to 30 parts by mass and more preferably 3 to 20 parts by mass with respect to 100 parts by mass of the benzoxazine resin (A).
- the benzoxazine resin composition can be blended with, for example, nanocarbon, a flame retardant, a mold release agent, or the like as long as the physical properties are not impaired.
- nanocarbon include carbon nanotubes, fullerenes, and derivatives thereof.
- flame retardant include phosphoric acid such as red phosphorus, triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, xylenyl diphenyl phosphate, resorcinol bisphenyl phosphate, bisphenol A bisdiphenyl phosphate, etc.
- esters and boric acid esters include silicone oil, stearic acid ester, carnauba wax and the like.
- the kneading method of the benzoxazine resin composition is not particularly limited.
- a kneader, a planetary mixer, a twin screw extruder or the like is used.
- particle components such as flame retardants and inorganic fillers
- the liquid resin component is diffused.
- heating / cooling, pressurization / depressurization may be performed as necessary. From the viewpoint of storage stability, it is preferable to store in a refrigerator / freezer immediately after kneading.
- the viscosity of the benzoxazine resin composition is preferably 10 to 3000 Pa ⁇ s at 50 ° C. from the viewpoint of tack and drape. More preferably, it is 10 to 2500 Pa ⁇ s, and most preferably 100 to 2000 Pa ⁇ s. If it is less than 10 Pa ⁇ s, the change with time of the tack due to the sinking of the composition of the present invention may become large. On the other hand, when it exceeds 3000 Pa ⁇ s, the tack becomes weak, and the drape property may be lowered.
- the reinforcing fiber glass fiber, carbon fiber, graphite fiber, aramid fiber, boron fiber, alumina fiber, silicon carbide fiber or the like is preferable. Two or more kinds of these fibers may be mixed and used, but carbon fibers and graphite fibers are preferably used in order to obtain a molded product that is lighter and more durable.
- any type of carbon fiber or graphite fiber can be used depending on the application, but since it is possible to obtain a composite material having excellent impact resistance and high rigidity and mechanical strength, tensile elasticity in the strand tensile test can be obtained.
- the rate is preferably 150 to 650 GPa, more preferably 200 to 550 GPa, still more preferably 230 to 500 GPa.
- the strand tensile test refers to a test performed based on JIS R7601 (1986) after impregnating a bundle of carbon fibers with a resin having the following composition and curing it at a temperature of 130 ° C. for 35 minutes.
- the form of the reinforcing fiber is not particularly limited, and for example, a long fiber aligned in one direction, a tow, a woven fabric, a mat, a knit, a braid, a short fiber chopped to a length of less than 10 mm, or the like is used.
- the long fiber is a single fiber or a fiber bundle substantially continuous for 10 mm or more.
- a short fiber is a fiber bundle cut into a length of less than 10 mm.
- an array in which reinforcing fiber bundles are aligned in a single direction is most suitable for applications that require a high specific strength and specific elastic modulus. Arrangements are also suitable for the present invention.
- the manufacturing method of the fiber reinforced resin composite material 1 is demonstrated.
- the prepreg material 4 that forms the outer plate portion 2 and the reinforcing portion 3 are prepared.
- the prepreg material 4 is obtained by impregnating reinforcing fibers with the benzoxazine resin composition described above.
- the impregnation method include a wet method in which a benzoxazine resin composition is dissolved in a solvent such as methyl ethyl ketone and methanol to lower the viscosity and impregnation, a hot melt method in which the viscosity is reduced by heating and impregnation (dry method), and the like. Can do.
- the wet method is a method in which the reinforcing fiber is immersed in a solution of the benzoxazine resin composition, then pulled up, and the solvent is evaporated using an oven or the like.
- the hot melt method is a benzoxazine resin composition whose viscosity is reduced by heating. By directly impregnating the reinforcing fiber into the fiber, or by preparing a film once coated with a benzoxazine resin composition on a release paper, etc., and then superposing the film from both sides or one side of the reinforcing fiber and heating and pressing. This is a method of impregnating a reinforcing fiber with a resin.
- the hot melt method is preferable because substantially no solvent remains in the prepreg.
- the prepreg material 4 preferably has a reinforcing fiber amount of 70 to 3000 g / m 2 per unit area.
- the amount of reinforcing fibers is less than 70 g / m 2, it is necessary to increase the number of laminated layers in order to obtain a predetermined thickness when forming a fiber reinforced composite material, and the work may be complicated.
- the amount of reinforcing fibers exceeds 3000 g / m 2 , the prepreg drapability tends to deteriorate. If the prepreg material 4 is a flat surface or a simple curved surface, the amount of reinforcing fibers may exceed 3000 g / m 2 .
- the fiber weight content is preferably 30 to 90% by mass, more preferably 35 to 85% by mass, and still more preferably 40 to 80% by mass.
- the fiber weight content is less than 30% by mass, the amount of the resin is too large to obtain the advantages of the fiber reinforced composite material excellent in specific strength and specific elastic modulus, or when the fiber reinforced composite material is molded at the time of curing. The amount of heat generated may be too large.
- the fiber weight content exceeds 90% by weight, resin impregnation failure occurs, and the resulting composite material may have many voids.
- the outer plate portion forming step (simple shape portion forming step) is executed.
- the outer plate portion 2 is formed by laminating the prepreg material 4.
- stacking in order to improve the adhesiveness of a laminated body, you may laminate
- the laminate may be shaped by a press molding method, a hot drape molding method, or a vacuum bagging molding method before or after installation in the mold.
- a preform 34 is formed with reinforcing fibers 33 so as to have the shape of the reinforcing portion 3.
- the preform may be heat-sealed using a thermoplastic material or the like (preferably the same component as that used for the resin) in order to maintain the shape. Further, a three-dimensional fabric or the like may be used.
- FIG. 3 is an explanatory view showing a state of the reinforcing portion integration step.
- the outer plate portion 2 and the preform 34 are set in the mold 5 for forming the fiber reinforced resin composite material 1, and the resin is pumped into the mold 5.
- the resin to be pumped is desirably the above-described benzoxazine resin composition.
- the pumped resin is flowed out of the mold 5 by the vacuum pump 51.
- the benzoxazine resin composition 41 fed to the outer plate portion 2 and the preform 34 is cured to form the reinforcing portion 3, and the outer plate portion 2 and the reinforcing portion. 3 is integrated.
- the outer plate portion 2 and the reinforcing portion 3 are formed of the same component resin (benzoxazine resin composition), the joint surface between the two and the interface after the integration. In addition, strength reduction can be suppressed.
- the resin components forming the outer plate portion 2 and the reinforcing portion 3 are different from each other, and the resin is compatible and the interface layer is not observed, what kind of resin is the compatible portion? It is unclear and difficult to design. Further, since the linear expansion coefficient differs when the resin components are different, it becomes a factor that causes warping of the fiber reinforced resin composite material 1 when it is removed from the mold after curing.
- the outer plate portion 2 and the reinforcing portion 3 are formed of the same component resin as described above, the resin of the compatible portion can be specified, and the difference in linear expansion coefficient does not occur. It is also possible to prevent malfunctions. Furthermore, if the outer plate portion 2 and the reinforcing portion 3 are formed of the same component resin, the same data can be acquired as the design allowable value for the outer plate portion 2 and the reinforcing portion 3.
- the present invention is not limited to the above embodiment, and can be modified as appropriate.
- the case where the matched die forming method is used in the reinforcing portion integration step has been described as an example.
- other forming methods are used.
- molding methods other than the matched die molding method include a vacuum resin impregnation method (VaRTM).
- VaRTM vacuum resin impregnation method
- the auxiliary material such as a vacuum pack that is indispensable in the vacuum resin impregnation method can be omitted, and the auxiliary material cost, the cost for discarding the auxiliary material, and the like can be reduced.
- the dimensional accuracy is superior to the vacuum resin impregnation method.
- stacking the several prepreg material 4 the outer-plate part 2 may be formed from the prepreg material 4 of 1 sheet.
- the reinforcing portion 3 such as a longitudinal member has been described as an example of the complicated shape portion.
- the complicated shape portion is another member that is required to have a bonding strength with a simple shape portion such as a bracket. Also good.
- the prepreg material 4 is formed into a sheet having a thickness of 0.14 mm, a width of 420 mm, and a depth of 210 mm by a benzoxazine resin composition (NF-34 (trade name): manufactured by JX Nippon Oil & Energy Corporation). Yes.
- the reinforcing fiber in the prepreg material 4 is carbon fiber (T700G (trade name): manufactured by Toray Industries, Inc.), and FAW (Fiber Areal Weight) is 150 g / m 2 and RC is 25 wt%.
- Sixteen prepreg materials 4 are laminated so that the directions of the carbon fibers are deviated by 45 degrees, and are integrally molded to form the outer plate portion 2.
- the thickness of the outer plate part 2 is 2.24 mm.
- the reinforcing portion 3 is a sheet-like one different from the above-described shape in order to simplify the experiment.
- the base material forming the reinforcing portion 3 is a sheet-like four-layer NCF (Non Crimp Fabrics) having a thickness of 0.68 mm, a width of 420 mm, and a depth of 210 mm.
- the reinforcing fibers of this four-layer woven NCF is, carbon fiber: a (T700G (trade name) manufactured by Toray Co., Ltd.), FAW is 692g / m 2 (per layer 173g / m 2).
- the fiber reinforced resin composite material 1 as an example is formed by pressure-feeding into a mold, heating and press-molding after flow-out, and integrally molding.
- Comparative Example 1 In Comparative Example 1, the resin forming the prepreg material 4 is an epoxy resin (Y24S31R150 (product number): manufactured by JX Nippon Oil & Energy Corporation), and the resin forming the reinforcing portion 3 is an epoxy resin (EPOLAM5015 (trade name): Axson. The conditions are the same as in the example except that the product is manufactured by the company. [Comparative Example 2] Comparative Example 2 has the same conditions as Comparative Example 1 except that the resin forming the reinforcing portion 3 is an epoxy resin (PR520 (trade name): manufactured by Cvtec).
- PR520 trade name
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Abstract
Description
近年、上述のような単純形状部と複雑形状部とを効率的に一体化するために、真空樹脂含浸法(VaRTM:Vacuum-assisted Resin Transfer Molding)により、繊維強化樹脂複合材を形成する技術が開発されている(例えば非特許文献1参照)。
このため、本発明の課題は、単純形状部と複雑形状部との界面を起因とした強度低下を抑制することである。
強化繊維に樹脂を含浸させた少なくとも一枚のシート状のプリプレグ材からなる単純形状部と、
前記単純形状部に対して一体的に形成され、強化繊維に樹脂を含浸させてなる複雑形状部とを備え、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが同じ成分であることを特徴としている。
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが、ベンゾオキサジン樹脂組成物であることを特徴としている。
前記ベンゾオキサジン樹脂組成物は、
分子中に式(1)で表されるベンゾオキサジン環を有する化合物と、エポキシ樹脂と、硬化剤と、靭性向上剤とを含むことを特徴としている。
強化繊維に樹脂を含浸させた少なくとも一枚のシート状のプリプレグ材から単純形状部を形成する単純形状部形成工程と、
強化繊維に樹脂を含浸させてなる複雑形状部を前記単純形状部に対して一体的に形成する複雑形状部一体化工程とを含み、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが同じ成分であることを特徴としている。
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが、ベンゾオキサジン樹脂組成物であることを特徴としている。
補強部3は、外板部2に固定される台座部31と、台座部31の中央から立設するリブ32とを備えている。この補強部3も、強化繊維を樹脂に含浸させて形成されている。外板部2をなすプリプレグ材4で用いられる樹脂と、補強部3で用いられる樹脂とは同成分である。
この樹脂は、ベンゾオキサジン樹脂組成物であり、分子中に式(1)で表されるベンゾオキサジン環を有する(A)化合物と、(B)エポキシ樹脂と、(C)硬化剤と、(D)靭性向上剤とを含んでいる。
炭素数1~12の鎖状アルキル基としては、例えば、メチル基、エチル基、プロピル基、イソプロピル基、n-ブチル基、イソブチル基、t-ブチル基が挙げられる。
炭素数3~8の環状アルキル基としては、例えば、シクロペンチル基、シクロヘキシル基が挙げられる。
炭素数1~12の鎖状アルキル基若しくはハロゲンで置換されたフェニル基としては、例えば、フェニル基、o-メチルフェニル基、m-メチルフェニル基、p-メチルフェニル基、o-エチルフェニル基、m-エチルフェニル基、p-エチルフェニル基、o-t-ブチルフェニル基、m-t-ブチルフェニル基、p-t-ブチルフェニル基、o-クロロフェニル基、o-ブロモフェニル基が挙げられる。
R1としては、上記例示の中でも良好な取り扱い性を与えることから、メチル基、エチル基、プロピル基、フェニル基、o-メチルフェニル基が好ましい。
以下、市販品を例示する場合、液状のものには、後述の動的粘弾性測定装置により得られる25℃における複素粘弾性率η*を粘度として記載している。
グリシジルアニリン類の市販品としては、例えば、GAN(粘度:120mPa・s)、GOT(粘度:60mPa・s)(以上、日本化薬(株)製)が挙げられる。
また、フェノールを前駆体とするエポキシ樹脂をウレタンやイソシアネートで変性したエポキシ樹脂も、このタイプに含まれる。
固形もしくは半固形のビスフェノールA型エポキシ樹脂の市販品としては、例えば、「jER」834、「jER」1001、「jER」1002、「jER」1003、「jER」1004、「jER」1004AF、「jER」1007、「jER」1009(以上、三菱化学(株)製)が挙げられる。
固形のビスフェノールF型エポキシ樹脂の市販品としては、例えば、4004P、「jER」4007P、「jER」4009P(以上、三菱化学(株)製)、「エポトート」YDF2001、「エポトート」YDF2004(以上、新日鐵化学(株)製)が挙げられる。
ビフェニル骨格を有するエポキシ樹脂の市販品としては、例えば、「jER」YX4000H、「jER」YX4000、「jER」YL6616(以上、三菱化学(株)製)、NC-3000(日本化薬(株)製)が挙げられる。
クレゾールノボラック型エポキシ樹脂の市販品としては、例えば、「エピクロン」N-660、「エピクロン」N-665、「エピクロン」N-670、「エピクロン」N-673、「エピクロン」N-695(以上、DIC(株)製)、EOCN-1020、EOCN-102S、EOCN-104S(以上、日本化薬(株)製)が挙げられる。
ナフタレン骨格を有するエポキシ樹脂の市販品としては、例えば、「エピクロン」HP4032(DIC(株)製)、NC-7000、NC-7300(以上、日本化薬(株)製)が挙げられる。
トリスフェニルメタン型エポキシ樹脂の市販品としては、例えば、TMH-574(住友化学(株)製)が挙げられる。
ウレタンおよびイソシアネート変性エポキシ樹脂の市販品としては、例えば、オキサゾリドン環を有するAER4152(旭化成イーマテリアルズ(株)製)が挙げられる。
ヘキサヒドロフタル酸ジグリシジルエステルの市販品としては、例えば、「エポミック」R540(粘度:350mPa・s)(三井化学(株)製)、AK-601(粘度:300mPa・s)(日本化薬(株)製)が挙げられる。
ダイマー酸ジグリシジルエステルの市販品としては、例えば、「jER」871(粘度:650mPa・s)(三菱化学(株)製)、「エポトート」YD-171(粘度:650mPa・s)(新日鐵化学(株)製)が挙げられる。
25℃で固形のエポキシ樹脂としては、芳香族含有量の高いエポキシ樹脂が難燃性を高めるために好ましく、例えば、ビフェニル骨格をもつエポキシ樹脂や、ナフタレン骨格をもつエポキシ樹脂、フェノールアラルキル型エポキシ樹脂が挙げられる。
これら硬化剤は(A)化合物のベンゾオキサジンや(B)エポキシ樹脂と反応することで、耐熱・耐湿性に優れる樹脂組成物あるいは繊維強化複合材料を得ることができる。
例えば、反応性エラストマー、ハイカーCTBN変性エポキシ樹脂、ハイカーCTB変性エポキシ樹脂、ウレタン変性エポキシ樹脂、ニトリルゴム添加エポキシ樹脂、架橋アクリルゴム微粒子添加エポキシ樹脂、シリコーン変性エポキシ樹脂、熱可塑性エラストマー添加エポキシ樹脂が使用できる。
有機微粒子としては、例えば、熱硬化性樹脂微粒子、熱可塑性樹脂微粒子またはこれらの混合物を用いることができる。
熱硬化性樹脂微粒子としては、例えば、エポキシ樹脂微粒子、フェノール樹脂微粒子、メラミン樹脂微粒子、ウレア樹脂微粒子、シリコーン樹脂微粒子、ウレタン樹脂微粒子またはこれらの混合物等が挙げられる。
重合法としては、例えば、乳化重合、ソープフリー乳化重合、分散重合、シード重合、懸濁重合またはこれらを互いに併用した方法があり、粒径が微細で、一部架橋構造、コア/シェル構造、中空構造、極性構造(エポキシ基、カルボキシル基、水酸基など)を有する微粒子が得られる、乳化重合、シード重合が用いられる。これらにより得られる一部架橋微粒子、コア/シェル型微粒子が好ましく用いられる。
コア/シェル型微粒子の市販されているものとして、スタフィロイドAC3355(商品名、ガンツ化成(株)製)、MX120(商品名、カネカ社製)等が挙げられる。
ナノカーボンとしては、例えば、カーボンナノチューブ、フラーレンやそれぞれの誘導体が挙げられる。
難燃剤としては、例えば、赤燐、トリフェニルホスフェート、トリクレジルホスフェート、トリキシレニルホルフェート、クレジルジフェニルホスフェート、キシレニルジフェニルホスフェート、レゾルシノールビスフェニルホスフェート、ビスフェノールAビスジフェニルホスフェート等のリン酸エステルや、ホウ酸エステル等が挙げられる。
離型剤としては、例えば、シリコンオイル、ステアリン酸エステル、カルナウバワックス等が挙げられる。
まず、外板部2を形成するプリプレグ材4と、補強部3とを準備する。
プリプレグ材4は、上述したベンゾオキサジン樹脂組成物を強化繊維に含浸させてなるものである。含浸させる方法としては、ベンゾオキサジン樹脂組成物をメチルエチルケトン、メタノール等の溶媒に溶解して低粘度化し、含浸させるウェット法、加熱により低粘度化し、含浸させるホットメルト法(ドライ法)等を挙げることができる。
ウェット法は、強化繊維をベンゾオキサジン樹脂組成物の溶液に浸漬した後、引き上げ、オーブン等を用いて溶媒を蒸発させる方法であり、ホットメルト法は、加熱により低粘度化したベンゾオキサジン樹脂組成物を直接強化繊維に含浸させる方法、又は一旦ベンゾオキサジン樹脂組成物を離型紙等の上にコーティングしたフィルムを作製しておき、次いで強化繊維の両側又は片側から前記フィルムを重ね、加熱加圧することにより強化繊維に樹脂を含浸させる方法である。
ホットメルト法においては、プリプレグ中に残留する溶媒が実質上皆無となるため好ましい。
また、繊維重量含有率は、好ましくは30~90質量%であり、より好ましくは35~85質量%であり、更に好ましくは40~80質量%である。繊維重量含有率が30質量%未満では、樹脂の量が多すぎて、比強度と比弾性率に優れる繊維強化複合材料の利点が得られなかったり、繊維強化複合材料の成形の際、硬化時の発熱量が大きくなりすぎることがある。繊維重量含有率が90重量%を超えると、樹脂の含浸不良が生じ、得られる複合材料はボイドの多いものとなる恐れがある。
ここで、外板部2と補強部3とをそれぞれなす樹脂の成分が異なる場合であって、樹脂が相容し界面層が観察されない場合には相容部はどのような樹脂であるかが不明確であり、設計する上で困難となる。また、樹脂の成分が異なると線膨張係数が異なるため、硬化後に金型から外した際に、繊維強化樹脂複合材1に反りを発生させる要因となる。
しかしながら、上述したように同一成分の樹脂で外板部2と補強部3とが形成されていれば、相容部の樹脂も特定することができ、線膨張係数の異なりも発生しないため、上述した不具合も防止することができる。さらに、同一成分の樹脂で外板部2と補強部3とが形成されていると、外板部2と補強部3とで設計許容値として同じデータを取得することができる。
例えば、上記実施形態では、補強部一体化工程でマッチドダイ成形法を用いる場合を例示して説明したが、外板部2と補強部3とを一体化できるのであればその他の成形法を用いてもよい。マッチドダイ成形法以外の成形法としては、例えば真空樹脂含浸法(VaRTM)が挙げられる。なお、マッチドダイ成形法であれば、真空樹脂含浸法では不可欠のバキュームパック等の副資材を省略することができ、副資材費や、副資材廃棄用の費用等を削減することが可能である。また、寸法精度についても真空樹脂含浸法と比して優れている。
また、上記実施形態では、複数のプリプレグ材4を積層してなる外板部2を例示して説明したが、外板部2は一枚のプリプレグ材4から形成されていてもよい。
さらに、上記実施形態では、複雑形状部として縦通材等の補強部3を例示して説明したが、複雑形状部としてはブラケット等単純形状部との接合強度が求められる他の部材であってもよい。
プリプレグ材4は、ベンゾオキサジン樹脂組成物(NF-34(商品名):JX日鉱日石エネルギー(株)社製)によって、厚さ0.14mm、幅420mm、奥行き210mmのシート状に形成されている。プリプレグ材4内の強化繊維は、炭素繊維(T700G(商品名):東レ(株)社製)であり、FAW(Fiber Areal Weight)が150g/m2、RC25wt%となっている。このプリプレグ材4を炭素繊維の方向が45度ずつずれるように16枚積層し、一体成形することで外板部2が形成されている。これにより外板部2の厚みは2.24mmとなっている。
補強部3は、実施例においては実験を簡素化すべく上述した形状とは異なりシート状のものを用いている。補強部3をなす基材は、厚さ0.68mm、幅420mm、奥行き210mmのシート状の四層織NCF(Non Crimp Fabrics)である。この四層織NCFの強化繊維は、炭素繊維(T700G(商品名):東レ(株)社製)であり、FAWが692g/m2(1層あたり173g/m2)である。これ(四層織NCF)をプリプレグ材4の上に3枚積層し、金型内にセットした後に、ベンゾオキサジン樹脂組成物(NF-34(商品名):JX日鉱日石エネルギー(株)社製)を金型内に圧送し、フローアウト後に加熱・加圧成形し、一体成形することで実施例となる繊維強化樹脂複合材1が形成される。
比較例1は、プリプレグ材4をなす樹脂をエポキシ樹脂(Y24S31R150(品番):JX日鉱日石エネルギー(株)社製)とし、補強部3をなす樹脂をエポキシ樹脂(EPOLAM5015(商品名):Axson社製)とした以外は実施例と同条件である。
[比較例2]
比較例2は、補強部3をなす樹脂をエポキシ樹脂(PR520(商品名):Cvtec社製)とした以外は比較例1と同条件である。
実施例、比較例1、比較例2に対して、ASTM規格 D2344に準拠する手法で層間せん断強度を測定した。また、実施例、比較例1、比較例2に対して、ASTM規格 D6272に準拠する手法で四点曲げ強度を測定した。
なお、実施例、比較例1、比較例2の各プリプレグ材4を炭素繊維の方向が45度ずつずれるように32枚積層し、一体成形した外板部2のみのものに対しても、上記の手法で層間せん断強度と四点曲げ強度とを測定し比較した。
2 外板部(単純形状部)
3 補強部(複雑形状部)
4 プリプレグ材
5 金型
6 金型
31 台座部
32 リブ
33 強化繊維
34 プリフォーム
51 真空ポンプ
61 ベンゾオキサジン樹脂組成物
Claims (6)
- 強化繊維に樹脂を含浸させた少なくとも一枚のシート状のプリプレグ材からなる単純形状部と、
前記単純形状部に対して一体的に形成され、強化繊維に樹脂を含浸させてなる複雑形状部とを備え、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが同じ成分であることを特徴とする繊維強化樹脂複合材。 - 請求項1に記載の繊維強化樹脂複合材において、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが、ベンゾオキサジン樹脂組成物であることを特徴とする繊維強化樹脂複合材。 - 強化繊維に樹脂を含浸させた少なくとも一枚のシート状のプリプレグ材から単純形状部を形成する単純形状部形成工程と、
強化繊維に樹脂を含浸させてなる複雑形状部を前記単純形状部に対して一体的に形成する複雑形状部一体化工程とを含み、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが同じ成分であることを特徴とする繊維強化複合材の製造方法。 - 請求項4に記載の繊維強化樹脂複合材の製造方法において、
前記プリプレグ材に用いられる樹脂と、前記複雑形状部に用いられる樹脂とが、ベンゾオキサジン樹脂組成物であることを特徴とする繊維強化複合材の製造方法。
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CN103857731A (zh) | 2014-06-11 |
US20180230306A1 (en) | 2018-08-16 |
EP2762520B1 (en) | 2020-11-11 |
EP2762520A1 (en) | 2014-08-06 |
KR20140054184A (ko) | 2014-05-08 |
EP2762520A4 (en) | 2015-05-27 |
US20140343191A1 (en) | 2014-11-20 |
US10752773B2 (en) | 2020-08-25 |
KR101642616B1 (ko) | 2016-07-25 |
CN103857731B (zh) | 2017-06-13 |
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