WO2016043037A1 - 繊維強化樹脂成形材料 - Google Patents
繊維強化樹脂成形材料 Download PDFInfo
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- WO2016043037A1 WO2016043037A1 PCT/JP2015/074736 JP2015074736W WO2016043037A1 WO 2016043037 A1 WO2016043037 A1 WO 2016043037A1 JP 2015074736 W JP2015074736 W JP 2015074736W WO 2016043037 A1 WO2016043037 A1 WO 2016043037A1
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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
- C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
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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
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
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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
- C08J5/02—Direct processing of dispersions, e.g. latex, to articles
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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
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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
- C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
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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
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
- C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
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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
- C08J2335/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least one other carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Derivatives of such polymers
- C08J2335/02—Characterised by the use of homopolymers or copolymers of esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/004—Additives being defined by their length
Definitions
- the present invention relates to a fiber-reinforced resin molding material, and in particular, it is possible to balance both the good fluidity of the material when molding with the molding material and the excellent mechanical properties of the molded product after molding in a well-balanced manner.
- the present invention relates to a novel fiber reinforced resin molding material.
- a fiber reinforced resin molding material composed of a bundle of discontinuous reinforcing fibers (for example, carbon fibers) (hereinafter sometimes referred to as fiber bundle) and a matrix resin (for example, thermosetting resin), heating
- a matrix resin for example, thermosetting resin
- Patent Documents 1 to 5 Techniques for forming a molded body having a desired shape by pressure molding are known (for example, Patent Documents 1 to 5).
- the fiber bundle in the fiber reinforced resin molding material is composed of a certain number of single-fiber bundles formed from predetermined strands, the fiber bundle is composed of a large number of single-fiber bundles. Molding materials tend to be inferior in the mechanical properties of molded products, while being excellent in fluidity during molding.
- Patent Document 1 discloses a molding material in which the number of filaments of a chopped fiber bundle in the molding material is defined within a range of 10,000 to 700,000.
- the reinforcing fibers can be efficiently moved in the form of a fiber bundle together with the resin during molding, so that excellent fluidity can be obtained.
- stress concentration will occur at the end of the fiber bundle in the molded product when the molded product breaks, and it is not suitable for molding molded products that require high mechanical properties. .
- Patent Document 2 discloses a fiber reinforced resin in which a fiber bundle that has been split so that the number of single yarns is 100 or less is disclosed. Since the number of single yarns in the bundle is small, the reinforcing fibers are well dispersed in the molded product, and the possibility of stress concentration occurring at the end of the fiber bundle in the molded product is reduced and the mechanical properties of the molded product are improved. On the other hand, there is a possibility that the fluidity as high as expected cannot be obtained during molding.
- the fiber reinforced resin molding material using a fiber bundle having a relatively large number of single yarns has a high production efficiency and tends to obtain excellent fluidity during molding, but the mechanical properties of the molded product are inferior.
- fiber reinforced resin molding materials using fiber bundles having a relatively small number of single yarns tend to have high mechanical properties of molded products, but hardly have high fluidity during molding.
- the object of the present invention is to pay attention to the above-mentioned tendency in the prior art, and a fiber-reinforced resin molding material capable of balancing both good fluidity during molding and excellent mechanical properties of the molded product in a balanced manner. Is to provide.
- a fiber-reinforced resin molding material is a fiber-reinforced resin molding material including at least a discontinuous bundle of reinforcing fibers and a matrix resin, and the bundle of reinforcing fibers.
- a reinforced fiber assembly A formed by cutting a strand of continuous reinforcing fibers after splitting the strands of continuous reinforcing fibers into a plurality of bundles, and then performing the splitting process.
- a continuous reinforcing fiber strand is formed in the molding material after being subjected to split fiber processing for completely dividing the strand into a plurality of bundles and then cut.
- Reinforcing fiber assembly A that is, reinforcing fiber assembly A having a relatively small number of single yarns by splitting treatment
- unsplit fiber that has not undergone splitting treatment or / and has insufficient splitting treatment
- a reinforcing fiber assembly B including a portion that is, a reinforcing fiber assembly B having a relatively large number of single yarns
- the ratio is in a specific range of 5 to 50%.
- the reinforcing fiber assembly A having a small number of single yarns can contribute to the improvement of the mechanical properties of the molded product after molding, and the reinforcing fiber assembly B having a large number of single yarns can contribute to the improvement of fluidity at the time of molding.
- the weight ratio of the aggregate B within a specific range, the fluidity and the mechanical characteristics are balanced as the characteristics within the target range.
- the average fiber length of the reinforcing fiber assembly A and the reinforcing fiber assembly B is preferably in the range of 5 to 100 mm. If the average fiber length is less than 5 mm, the reinforcing effect of the molded product with reinforcing fibers may be insufficient, and if the average fiber length exceeds 100 mm, good flow becomes difficult during molding and fluidity decreases. Or the reinforcing fiber may bend easily.
- the number of single yarns of each reinforcing fiber assembly A is preferably in the range of 800 to 10,000. If the number of single yarns of the reinforcing fiber assembly A is less than 800, high mechanical properties of the molded product can be easily obtained, but there is a possibility that the fluidity during molding is greatly reduced, and if it exceeds 10,000, Although improvement in fluidity can be expected, there is a risk that stress concentration is likely to occur in the molded product, so that sufficiently high mechanical properties may not be expected, and the reinforcing fiber assembly A and the reinforcing fiber formed through split fiber processing The difference from the aggregate B becomes unclear, and the basic concept of the present invention that attempts to mix these reinforcing fiber aggregates A and B may be impaired.
- the type of reinforcing fiber used is not particularly limited, and any reinforcing fiber such as carbon fiber, glass fiber, aramid fiber, or a combination thereof can be used.
- the effect of the present invention is particularly great when the reinforcing fiber is made of carbon fiber.
- thermosetting resin As the matrix resin in the fiber-reinforced resin molding material according to the present invention, either a thermosetting resin or a thermoplastic resin can be used.
- the fiber-reinforced resin molding material according to the present invention as described above can be manufactured by, for example, the following method. That is, a method for producing a fiber-reinforced resin molding material comprising at least a discontinuous bundle of reinforcing fibers and a matrix resin, wherein the strands of continuous reinforcing fibers are used as the bundle of reinforcing fibers.
- Reinforcing fiber assembly A formed by being cut after splitting treatment that is completely divided into a plurality of bundles, and the splitting process is not performed or / and the splitting process is insufficient
- Both the reinforcing fiber assembly B including the unbroken fiber part are used, and the amount of the reinforcing fiber assembly B used is such that the weight ratio of the reinforcing fiber assembly B to the total weight of the reinforcing fibers in the material is 5 to 50 It is a method of controlling to be in the range of%.
- the fiber-reinforced resin molding material according to the present invention it is possible to achieve both good fluidity during molding and excellent mechanical properties of the molded product in a balanced manner. Moreover, since large tow having a large number of single yarns can be used as the strands of continuous reinforcing fibers for producing the reinforcing fiber assemblies A and B, it is possible to improve productivity and reduce manufacturing costs.
- the present invention is a fiber-reinforced resin molding material comprising at least a discontinuous bundle of reinforcing fibers and a matrix resin, wherein the reinforcing fiber assembly is a continuous reinforcing fiber strand into a plurality of bundles.
- Reinforced fiber assembly A formed by being cut after being subjected to splitting treatment to be completely divided, and unsplit parts where the splitting process is not performed or / and the splitting process is insufficient
- a reinforcing fiber assembly B containing both, and the ratio of the weight of the reinforcing fiber assembly B to the total weight of the reinforcing fibers in the material is in the range of 5 to 50%.
- Such a fiber reinforced resin molding material according to the present invention uses, for example, both the reinforcing fiber assembly A and the reinforcing fiber assembly B, and the amount of the reinforcing fiber assembly B used is changed to the reinforcing fiber in the material.
- the ratio of the weight of the reinforcing fiber assembly B to the total weight is controlled so as to fall within the range of 5 to 50%.
- the reinforcing fiber assembly A and the reinforcing fiber assembly B are formed, for example, as shown in FIG.
- the vertical direction of the paper surface of FIG. 1 indicates the direction in which the continuous reinforcing fibers of the strand extend.
- the split fiber treatment for completely dividing the strand 1 into a plurality of bundles when viewed in the width direction of the strand 1 is performed.
- the split fiber part 2 and the non-split part 3 that is not subjected to the split fiber process and / or insufficiently split fiber process are formed. After this split fiber processing is performed, as shown in FIG.
- a large number of reinforcing fiber assemblies A and reinforcing fiber assemblies B formed as described above are used, and the amount of the reinforcing fiber assembly B used is the reinforcing fiber assembly with respect to the total weight of the reinforcing fibers in the material.
- the weight ratio of B is controlled so as to fall within the range of 5 to 50%, and is used for molding a fiber reinforced resin molding material together with the matrix resin.
- FIG. 2 is a graph in which the horizontal axis represents the number of single yarns in the reinforcing fiber assembly, and the vertical axis represents the total weight of the reinforcing fiber assembly having the same number of single yarns.
- the example shown in FIG. 2 includes a relatively small number of single yarns.
- the reinforcing fiber assembly A and the reinforcing fiber assembly B composed of a relatively large number of single yarns are shown as examples each having a weight-related peak on the horizontal axis.
- the integrated value of the area under the curve of the curve shown in this graph is considered to correspond to the total weight of the reinforcing fibers in the material, and the integrated value of the area under the curve in the region of a certain number of single yarns or more is the aggregate of reinforcing fibers. This is considered to correspond to the weight of the body B.
- the amount of the reinforcing fiber assembly B used is controlled so as to fall within a range of 5 to 50% as a ratio of the weight of the reinforcing fiber assembly B to the total weight of the reinforcing fibers in the material.
- the type of the reinforcing fiber used is not particularly limited, and any reinforcing fiber such as carbon fiber, glass fiber, aramid fiber or a combination thereof can be used,
- the effect of the present invention is particularly great when the reinforcing fiber is made of carbon fiber.
- the average fiber diameter is preferably 3 to 12 ⁇ m, more preferably 5 to 9 ⁇ m.
- a method for sizing treatment of reinforcing fibers a method in which carbon fibers are immersed in a solution in which a resin is dispersed in water or a solvent and then dried is preferable.
- the type of resin used as the sizing agent is not particularly limited, but is preferably compatible with the matrix resin, and is preferably the same type of resin as the matrix resin.
- thermosetting resin and thermoplastic resin can be used, and there is no particular limitation on the material of the thermosetting resin used for the carbon fiber composite material, It can be appropriately selected within a range in which the mechanical properties as a molded product are not significantly reduced.
- vinyl ester resin, epoxy resin, unsaturated polyester resin, phenol resin, epoxy acrylate resin, urethane acrylate resin, phenoxy resin, alkyd resin, urethane resin, maleimide resin, cyanate resin, and the like can be used.
- the material of the thermoplastic resin is not particularly limited, and can be appropriately selected as long as the mechanical properties as a molded product are not greatly deteriorated.
- polyolefin resins such as polyethylene resin and polypropylene resin
- polyamide resins such as nylon 6 resin and nylon 6,6 resin
- polyester resins such as polyethylene terephthalate resin and polybutylene terephthalate resin
- polyphenylene sulfide resin polyether A resin such as a ketone resin, a polyether sulfone resin, or an aromatic polyamide resin
- the continuous fiber subjected to the split fiber processing according to the present invention means that the continuous reinforcing fiber has a portion torn into a plurality of fiber bundles.
- continuous fibers subjected to split fiber processing can be obtained by periodically and locally blowing air from a direction perpendicular to the longitudinal direction of the continuous reinforcing fiber, but the split fiber processing method is particularly limited to this. Not.
- the strand of continuous reinforcing fiber that has been subjected to split fiber treatment is subjected to a cutting step of cutting to a predetermined length as shown in FIG. 1 (B) described above, but the cutting method in this cutting step is also particularly limited.
- a method of intermittently cutting the strand at a predetermined pitch in the longitudinal direction using a mechanical cutter can be employed.
- the reinforcing fiber assembly A formed by being cut after being subjected to the splitting treatment and the splitting treatment is not performed or / and splitting treatment is performed.
- Reinforcing fiber assembly B including an unbroken fiber portion with insufficient drip is dispersed, for example, so as to form a nonwoven fabric of reinforcing fiber assembly.
- the ratio of the weight of the reinforcing fiber assembly B to the total weight of the reinforcing fibers is controlled so as to fall within the range of 5 to 50%. Control can be performed by separately collecting the reinforcing fiber assembly A and the reinforcing fiber assembly B and mixing them at a predetermined ratio.
- the weight ratio of the reinforcing fiber assembly B to the total weight of the reinforcing fibers is estimated almost accurately in consideration of the ratio of the area of the split fiber processing portion to the total flat area of the strands of the continuous reinforcing fibers and the cutting length. It is possible. If the split fiber treatment conditions and the cutting treatment conditions are set so that the weight ratio falls within the predetermined range, a desired nonwoven fabric can be obtained simply by spraying the entire reinforcing fiber aggregate obtained after the cutting treatment. It is possible.
- the weight content of the reinforcing fiber with respect to the total weight of the fiber-reinforced tree molding material is preferably in the range of 30 to 60%, and preferably in the range of 35 to 50%. More preferred.
- the fiber length of the reinforcing fiber assembly according to the present invention is measured with a precision of 1 mm or less using a microscope or a caliper. Moreover, when each fiber length is not uniform in the single yarn in the reinforcing fiber assembly, the fiber length is calculated geometrically. For example, in the cutting step, when there is a certain reinforcing fiber assembly cut obliquely with respect to the fiber direction, the average value of the longest fiber length and the shortest fiber length in the reinforcing fiber assembly is the fiber length of the reinforcing fiber assembly. Can be considered.
- the average fiber length of the reinforcing fiber aggregate is preferably in the range of 5 to 100 mm, and more preferably in the range of 10 to 80 mm.
- the fiber length distribution may be a single fiber length distribution or a mixture of two or more.
- the weight of the reinforcing fiber aggregate in the present invention can be measured by measuring the weight of each reinforcing fiber aggregate from the collected sample and counting them, and is preferably measured with an accuracy of 1/100 mg or less.
- the number of single yarns in the reinforcing fiber assembly in the present invention is calculated by the following formula (1).
- the reinforcing fiber assembly A in the fiber-reinforced resin molding material according to the present invention may contain a small amount of an assembly obtained by further dividing the assembly in the cutting step, the spreading step, and the resin impregnation step after the split fiber treatment.
- Each reinforcing fiber assembly A preferably has a single yarn number in the range of 800 to 10,000. Further, when a range ⁇ in which the difference between the upper and lower limit numbers arbitrarily set in the range is within 1,000 is set, the number of aggregates of the aggregate A in the range ⁇ and the aggregate total The weight is preferably maximized when the number of single yarns is in the range of 800 to 10,000.
- the reinforcing fiber aggregate B in the fiber-reinforced resin molding material according to the present invention may contain a small amount of aggregates obtained by further dividing the aggregate in the cutting step, the spreading step, and the resin impregnation step after the split fiber treatment. It is preferable that all the reinforcing fiber assemblies having a single yarn number larger than the reinforcing fiber assembly A having a predetermined number of single yarns in the fiber reinforced resin molding material are regarded as the reinforcing fiber assembly B.
- the ratio (%) of the weight of the reinforcing fiber assembly B to the total reinforcing fiber weight of the fiber-reinforced resin molding material according to the present invention is calculated by the following formula (2).
- Weight ratio weight of reinforcing fiber assembly B / total weight of reinforcing fibers in fiber reinforced resin molding material ⁇ 100 ...
- the unit of length of the fiber bundle (fiber length) is mm and the unit of weight is g for the fiber reinforced resin molding material and its sample.
- the carbon fibers and thermosetting resins used in Examples and Comparative Examples are as follows.
- Carbon fiber Carbon fiber “Panex (registered trademark) R 35 Tow” manufactured by Zoltek (fiber diameter 7.2 ⁇ m, strand 50K (K is 1,000 fibers), tensile strength 4,137 MPa)
- Matrix resin Vinyl ester resin (manufactured by Dow Chemical Co., Ltd., “Delaken” (registered trademark))
- Curing agent tert-butyl peroxybenzoate (Nippon Yushi Co., Ltd., “Perbutyl (registered trademark) Z”) Thickener: Magnesium oxide (Kyowa Chemical Industry Co., Ltd., MgO # 40)
- the number of single yarns in each reinforcing fiber assembly was calculated by the following formula (1a).
- a reinforcing fiber assembly having an arbitrary number of single yarns in a certain range by splitting treatment was defined as a reinforcing fiber assembly A, and the total weight of the assembly A was measured. Further, the reinforcing fiber assembly having a larger number of single yarns than the reinforcing fiber assembly A was defined as a reinforcing fiber assembly B, and the total weight of the assembly B was measured.
- Mold No. that can produce flat plate 1 was used.
- a fiber reinforced resin molding material is used as a mold no. After being placed in the center of 1 (charge rate is about 50%), it is cured under a pressure of 10 MPa with a pressure press machine under conditions of about 130 ° C. for 6 minutes to obtain a 300 ⁇ 400 mm flat plate. It was. Cut 5 pieces (total 10 pieces) of 100 ⁇ 25 ⁇ 1.6 mm test pieces from 0 degree (flat direction of flat plate 0 degree) and 90 degree direction from the flat plate, and measure according to JIS K7074 (1988) Carried out.
- Example 1 As the carbon fiber, the aforementioned “Panex (registered trademark) R 35 Tow” was used. A continuous carbon fiber strand subjected to split fiber treatment is sprayed periodically and locally under predetermined conditions from a direction perpendicular to the fiber longitudinal direction of the continuous carbon fiber so as to be uniformly dispersed. As a result, a discontinuous carbon fiber nonwoven fabric having isotropic fiber orientation was obtained. A rotary cutter was used as the cutting device. The distance between the blades was 30 mm. Moreover, the basis weight of the discontinuous carbon fiber nonwoven fabric was 1 kg / m 2 .
- a sheet-like fiber reinforced resin molding material was obtained by impregnating a discontinuous carbon fiber nonwoven fabric with a resin in which 100 parts by weight of a matrix resin, 1 part by weight of a curing agent and 7 parts by weight of a thickening agent were impregnated with a roller.
- the fiber-reinforced resin molding material had a carbon fiber weight content of 40% and a density of 1.46 g / cm 3 .
- the measurement result of the weight ratio of the reinforced fiber assembly B was 25%.
- a fiber reinforced resin molding material is used as a mold no.
- the bending strength was 374 MPa.
- a fiber reinforced resin molding material is used as a mold no. In the molded product obtained by molding according to 2, no thinning and swelling were observed, but some fine wrinkles were generated on the surface (determination B).
- Example 2 The same procedure as in Example 1 was conducted except that the splitting treatment conditions were adjusted and the weight ratio of the reinforcing fiber assembly B was changed to 5%.
- Example 3 The same procedure as in Example 1 was conducted except that the splitting treatment conditions were adjusted and the weight ratio of the reinforcing fiber assembly B was 50%.
- Example 4 The interval between the blades of the rotary cutter was adjusted, and the same procedure as in Example 1 was performed except that the average fiber length of the reinforcing fiber assembly A and the reinforcing fiber assembly B was 5 mm.
- Example 5 The interval between the blades of the rotary cutter was adjusted, and the same procedure as in Example 1 was performed except that the average fiber length of the reinforcing fiber assembly A and the reinforcing fiber assembly B was set to 100 mm.
- Example 6 The same procedure as in Example 1 was conducted except that the splitting treatment conditions were adjusted and the number of single yarns in the range ⁇ of the reinforcing fiber assembly A was 1,000.
- Example 7 The same procedure as in Example 1 was conducted except that the splitting treatment conditions were adjusted and the number of single yarns in the range ⁇ of the reinforcing fiber assembly A was 10,000. The results in Examples 1 to 7 are shown in Table 2.
- Comparative Example 2 The weight ratio of the reinforcing fiber assembly B was 0%, and other than that was the same as in Example 1. The results in Comparative Examples 1 and 2 are shown in Table 3.
- the weight ratio of the reinforcing fiber assembly B is particularly in the range of 5 to 50% defined in the present invention, and good in molding. Excellent fluidity and excellent mechanical properties (particularly bending strength) of the molded product were able to be balanced.
- Comparative Example 1 since the weight ratio of the reinforcing fiber assembly B is 100%, the fluidity during molding was good, but the mechanical properties of the molded product were low.
- Comparative Example 2 Since the weight ratio of the reinforcing fiber assembly B is 0%, the excellent mechanical properties of the molded product can be achieved, but the fluidity during molding is poor, and the molded product has a lack of parts. (Decision E) In both Comparative Examples 1 and 2, good fluidity during molding and excellent mechanical properties of the molded product could not be balanced.
- the present invention can be applied to any fiber-reinforced resin molding material for which good flowability during molding and excellent mechanical properties of a molded product are desired to be balanced.
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Abstract
Description
本発明は、少なくとも不連続の強化繊維の束状集合体とマトリックス樹脂とを含む繊維強化樹脂成形材料であって、上記強化繊維集合体が、連続強化繊維のストランドが該ストランドを複数の束に完全分割する割繊処理を施された後切断されて形成された強化繊維集合体Aと、上記割繊処理が施されていない、または/および、上記割繊処理が不十分な未割繊部を含む強化繊維集合体Bとの両方を含み、材料中の強化繊維の総重量に対する上記強化繊維集合体Bの重量の割合が5~50%の範囲にあることを特徴とする繊維強化樹脂成形材料に関する。このような本発明に係る繊維強化樹脂成形材料は、例えば、上記強化繊維集合体Aと上記強化繊維集合体Bとの両方を用い、強化繊維集合体Bの使用量を、材料中の強化繊維の総重量に対する上記強化繊維集合体Bの重量の割合が5~50%の範囲に入るように制御することによって製造できる。
強化繊維集合体中の単糸数(本)=集合体の重量(g)×繊維長(m)/繊度(g/m)
・・・(1)
重量割合=強化繊維集合体Bの重量/繊維強化樹脂成形材料中の全強化繊維重量×100
・・・(2)
特に、注記が無い限り、繊維強化樹脂成形材料やその試料について、繊維束(繊維長)の長さの単位はmm、重量の単位はgである。なお、実施例、比較例で用いた炭素繊維や熱硬化性樹脂は以下のとおりである。
炭素繊維:Zoltek社製の炭素繊維“Panex(登録商標) R 35 Tow”(繊維径7.2μm、ストランド50K(Kは1,000本)、引張強度4,137MPa)
マトリックス樹脂:ビニルエステル樹脂(ダウ・ケミカル(株)製、“デラケン”(登録商標))
硬化剤: tert-ブチルパーオキシベンゾエート(日本油脂(株)製、“パーブチル(登録商標)Z”)
増粘剤:酸化マグネシウム(協和化学工業(株)製、MgO#40)
まず、繊維強化樹脂成形材料から100mm×100mmの試料を切り出し、前記試料を600℃×1時間、炉内にて加熱し樹脂を除去した。続いて、樹脂を除去した試料の重量を測定することにより、繊維強化樹脂成形材料中の全炭素繊維の重量を測定した。さらに、前記試料より強化繊維集合体をピンセットを用いて全て取り出し、各々の強化繊維集合体において重量を測定した。重量の測定には1/100mgまで測定可能な天秤を用いた。続いて、ピンセットを用いて取り出した各々の強化繊維集合体において繊維長をノギスを使用して1mm単位まで測定した。各強化繊維集合体中の単糸数を下記式(1a)により算出した。
各強化繊維集合体中の単糸数(本)=集合体の重量(g)×繊維長(m)/繊度(g/m)・・・(1a)
重量割合=強化繊維集合体Bの重量/繊維強化樹脂成形材料中の全炭素繊維重量×100・・・(2a)
平板を制作することが可能である金型No.1を用いた。繊維強化樹脂成形材料を金型No.1の中央部に配置(チャージ率にして50%程度)した後、加圧型プレス機により10MPaの加圧のもと、約130℃×6分間の条件により硬化させ、300×400mmの平板を得た。平板より0度(平板長手方向を0度)と90度方向から、それぞれ100×25×1.6mmの試験片を5片(合計10片)を切り出し、JIS K7074(1988年)に準拠し測定を実施した。
凹凸部およびリブ形成用の溝を有する金型No.2を使用した。繊維強化樹脂成形材料を金型No.2の中央部に配置(チャージ率にして50%程度)した後、加圧型プレス機により10MPaの加圧のもと、約130℃×6分間の条件により硬化させ、成形品を得た。成形品に対し下記表1に示す評価項目について目視観察をすることで、各々の成形品に対し総合的に流動特性の評価を行った。
炭素繊維として、前述した“ Panex(登録商標) R 35 Tow”を使用した。連続炭素繊維の繊維長手方向に垂直な方向から所定の条件で周期的かつ局部的にエアを吹き付けることにより割繊処理を施された連続炭素繊維ストランドを切断して均一分散するように散布することにより、繊維配向が等方的である不連続炭素繊維不織布を得た。切断装置にはロータリー式カッターを用いた。刃の間隔は30mmとした。また、不連続炭素繊維不織布の目付は1kg/m2であった。
割繊処理条件を調整し、強化繊維集合体Bの重量割合を5%とした以外は実施例1と同様にした。
割繊処理条件を調整し、強化繊維集合体Bの重量割合を50%とした以外は実施例1と同様にした。
ロータリー式カッターの刃の間隔を調整し、強化繊維集合体A、および強化繊維集合体Bの平均繊維長を5mmとした以外は実施例1と同様にした。
ロータリー式カッターの刃の間隔を調整し、強化繊維集合体A、および強化繊維集合体Bの平均繊維長を100mmとした以外は実施例1と同様にした。
割繊処理条件を調整し、強化繊維集合体Aの範囲αにおける単糸数を1,000本とした以外は実施例1と同様にした。
割繊処理条件を調整し、強化繊維集合体Aの範囲αにおける単糸数を10,000本とした以外は実施例1と同様にした。実施例1~7における結果を表2に示す。
強化繊維集合体Bの重量割合を100%とし、それ以外は実施例1と同様とした。
強化繊維集合体Bの重量割合を0%とし、それ以外は実施例1と同様とした。比較例1、2における結果を表3に示す。
2 割繊部
3 未割繊部
4 切断線
5 強化繊維集合体A
6 強化繊維集合体B
Claims (5)
- 少なくとも不連続の強化繊維の束状集合体とマトリックス樹脂とを含む繊維強化樹脂成形材料であって、前記強化繊維の束状集合体が、連続強化繊維のストランドが該ストランドを複数の束に完全分割する割繊処理を施された後切断されて形成された強化繊維集合体Aと、前記割繊処理が施されていない、または/および、前記割繊処理が不十分な未割繊部を含む強化繊維集合体Bとの両方を含み、材料中の強化繊維の総重量に対する前記強化繊維集合体Bの重量の割合が5~50%の範囲にあることを特徴とする繊維強化樹脂成形材料。
- 前記強化繊維集合体Aおよび強化繊維集合体Bの平均繊維長が5~100mmの範囲にある、請求項1に記載の繊維強化樹脂成形材料。
- 前記強化繊維集合体Aの単糸数が800~10,000の範囲にある、請求項1または2に記載の繊維強化樹脂成形材料。
- 前記強化繊維が炭素繊維からなる、請求項1~3のいずれかに記載の繊維強化樹脂成形材料。
- 前記マトリックス樹脂が熱硬化性樹脂または熱可塑性樹脂からなる、請求項1~4のいずれかに記載の繊維強化樹脂成形材料。
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TW201627364A (zh) | 2016-08-01 |
KR20170056581A (ko) | 2017-05-23 |
EP3195994A1 (en) | 2017-07-26 |
TWI688592B (zh) | 2020-03-21 |
US20170260345A1 (en) | 2017-09-14 |
CN106687267A (zh) | 2017-05-17 |
EP3195994B1 (en) | 2022-08-03 |
ES2926131T3 (es) | 2022-10-24 |
EP3195994A4 (en) | 2018-06-13 |
JP6119876B2 (ja) | 2017-05-10 |
CN106687267B (zh) | 2020-02-28 |
KR102366502B1 (ko) | 2022-02-23 |
JPWO2016043037A1 (ja) | 2017-04-27 |
US10392482B2 (en) | 2019-08-27 |
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