WO2016136792A1 - 樹脂供給材料、強化繊維の使用方法、プリフォーム、および繊維強化樹脂の製造方法 - Google Patents
樹脂供給材料、強化繊維の使用方法、プリフォーム、および繊維強化樹脂の製造方法 Download PDFInfo
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/88—Adding charges, i.e. additives
- B29B7/90—Fillers or reinforcements, e.g. fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
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- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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- B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
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Definitions
- the present invention relates to a resin supply material, a method for using a reinforced fiber, a preform, and a method for manufacturing a fiber reinforced resin.
- fiber reinforced resin Since fiber reinforced resin has excellent specific strength and specific rigidity, it is widely used in applications such as aircraft, automobiles and sports. Particularly in industrial applications such as automobiles and sports, there is an increasing demand for high-speed molding process of fiber reinforced resin.
- Examples of high-speed molding methods for fiber reinforced resins include the RTM (resin transfer molding) method (Patent Document 1) and the RFI (resin film infusion) method (Patent Document 2).
- RTM resin transfer molding
- RFI resin film infusion
- FRP (fiber reinforced plastic) member is molded by pouring into a mold and heat curing. Since a dry substrate is used, a three-dimensional complicated shape can be formed.
- thermosetting resin that is liquid at room temperature is not used as in the RTM method, the site is less likely to get dirty, and the time required for resin preparation and the like can be saved.
- thermosetting resin used in the RFI method is in the form of a film and has low rigidity, there is a problem that handling property is poor, and it takes time and labor to arrange the mold.
- Patent Documents 3 and 4 use an impregnated body in which a thermosetting resin that is liquid at room temperature is sucked into a soft support (described as a resin support in Patent Document 3 and a preform in Patent Document 4).
- a fiber reinforced resin molding method using SMC Sheet Molding Compound has been proposed in Japanese Patent Application Laid-Open No. 2005-26883.
- Patent Document 6 discloses a resin carrier having improved handling properties by filling a thermally stable holding body with an uncured oligomer film that has low strength and is easily damaged. A method for forming a fiber reinforced resin has been proposed.
- Patent Documents 3 and 4 can produce a structural member by laminating an impregnated body with a dry base material, and then heating and pressurizing in a mold and impregnating the reinforcing fiber base material with a thermosetting resin in the impregnated body. It can be said that since the support is impregnated with the resin, the impregnated body is excellent in handleability. However, since the carrier used has low mechanical properties and a narrow application viscosity range, there is a problem that desired physical properties cannot be obtained when a fiber reinforced resin is used.
- the purpose of using the molding method of Patent Document 5 is to smoothen the surface of the molded product by suppressing the formation of dents by interposing a non-impregnated base material between the prepreg layers.
- Another object is to obtain a molded article having good appearance quality. Therefore, the fiber content of the prepreg is high, and the rate of change of the fiber content before and after molding is small. It is difficult to use an unimpregnated base material having a high basis weight or to apply a resin supply material to uneven thickness molding.
- the molding method of Patent Document 6 can manufacture a structural member by laminating a resin carrier with a dry substrate and then impregnating the reinforcing fiber substrate with a thermosetting resin in the resin carrier by heating and pressing in a mold. And since the uncured resin film is filled in the thermally stable resin film, it can be said that the handleability of the resin carrier is excellent. However, there is a problem that it is necessary to open holes in the thermally stable resin film for allowing the uncured resin that melts by heating to flow out, and the process is complicated. Furthermore, since a hole is made in the thermally stable resin film before molding, there is a problem that the resin that can be filled is limited to a solid one from the viewpoint of leakage of the uncured resin.
- Patent Document 6 when the hole for allowing the uncured resin to flow out is not opened, the end of the film is melted at 290 ° C. or higher by adhering with an adhesive whose strength decreases when it exceeds 200 ° C. A method for supplying uncured resin is also described. In this case, since the outflow of the resin occurs only from the end portion of the film filled with the uncured resin, there is a problem that the resin content is different between the center and the end portion of the molded product. Moreover, there is no description about making uncured resin into a viscosity suitable for impregnation.
- the present invention has been made in view of the above, and an object of the present invention is to provide a resin supply material excellent in resin supportability, handleability, and mechanical properties, and a method for producing a fiber reinforced resin using the resin supply material. It is to provide.
- Another object of the present invention is to provide a resin supply material that is excellent in handleability regardless of the viscosity of the supplied resin, and a method for producing a fiber reinforced resin using the resin supply material.
- the resin supply material which concerns on the 1st aspect of this invention is a resin supply material used for shaping
- the fiber of the said reinforced fiber which consists of a reinforced fiber and resin and is represented by following formula (I)
- the weight content Wfi is 30% or less and / or the fiber volume content Vfi of the reinforcing fiber represented by the following formula (II) is 20% or less.
- Wfi Wf1 / (Wf1 + Wr1) ⁇ 100 (%)
- Wf1 Fiber weight in resin feed material
- Wr1 Resin weight in resin feed material
- Vfi Vf1 / Vp1 ⁇ 100 (%)
- Vf1 Fiber volume in resin feed material (mm 3 )
- Vp1 Volume of resin feed material (mm 3 )
- the resin supply material according to the second aspect of the present invention is a resin supply material used for molding a fiber reinforced resin, and is composed of a film made of a thermoplastic resin and a thermosetting resin.
- the value X obtained by dividing the tensile load F at the yield point measured in the test (JIS K 7127 (1999)) by the width W of the test piece is 1 N / mm or more at 25 ° C. and 1 N at the temperature T shown below. / Mm.
- Temperature T Temperature at which the viscosity of the thermosetting resin is minimized when the thermosetting resin is heated from 30 ° C. to a temperature increase rate of 1.5 ° C./min.
- the method for using a reinforcing fiber according to the present invention is a method for using a reinforcing fiber for use in a resin supply material composed of a reinforcing fiber and a resin used for molding a fiber-reinforced resin, and is represented by the following formula (V):
- the reinforcing fiber is used as a web having a thickness change rate R before and after molding within a range of 1.1 to 10.
- R t 0 / t 1 (V) t 0 : initial web thickness (mm) t 1 : Thickness (mm) in a state where the web is pressurized at 0.1 MPa
- the preform according to the present invention is formed by laminating and integrating the resin supply material according to the present invention and a base material.
- the method for producing a fiber reinforced resin according to the present invention supplies and molds the resin or the thermosetting resin from the resin supply material to the substrate by heating and pressurizing the preform according to the present invention.
- the present invention it is possible to provide a resin supply material excellent in resin supportability, handleability, and mechanical properties, and a method for producing a fiber reinforced resin using the resin supply material.
- the present invention it is possible to provide a resin supply material excellent in handleability regardless of the viscosity of the supplied resin, and a method for producing a fiber reinforced resin using the resin supply material.
- FIG. 1 is a schematic diagram showing the structure of a preform.
- the present invention is a resin supply material composed of reinforcing fibers and a resin.
- the resin supply material 1 is prepared by laminating the resin supply material 1 with a base material 2 to produce a preform 3, and heating and pressurizing the preform 3 in a closed space, for example.
- the fiber reinforced resin can be molded.
- the preform means a laminated body in which the resin supply material 1 and the substrate 2 are laminated and integrated, and a predetermined number of the resin supply materials 1 are laminated and the outermost layer of the integrated laminated body.
- a sandwich laminate in which the substrate 2 is sandwiched an alternate laminate in which the resin supply material 1 and the substrate 2 are alternately laminated, and a combination thereof. It is preferable to form a preform in advance because the base material 2 can be impregnated with the resin quickly and more uniformly in the production process of the fiber reinforced resin.
- the mold may be a double-sided mold such as a closed mold made of a rigid body or a single-sided mold.
- the preform 3 can be placed between the flexible film and the rigid open mold (in this case, the space between the flexible film and the rigid open mold is in a reduced pressure state from the outside, The preform 3 is in a pressurized state).
- the resin supply material 1 of the present invention is preferably made of a reinforcing fiber and a resin and is in the form of a sheet.
- the sheet thickness is preferably 0.5 mm or more, more preferably 1 mm or more, and even more preferably 1.5 mm or more from the viewpoint of resin supply property and mechanical properties.
- the sheet thickness is preferably a sheet shape of 100 mm or less, more preferably 60 mm or less, and further preferably 30 mm or less.
- the fiber weight content Wfi (before molding) represented by the following formula of the resin supply material 1 of the present invention is preferably 0.5% or more, more preferably 1.0% or more, and 1.5% or more. Further preferred. If the fiber weight content Wfi is less than 0.5%, the amount of the resin is too much with respect to the reinforcing fiber, and the resin cannot be supported on the reinforcing fiber, or a large amount of resin may flow outside during molding. is there. Moreover, the fiber weight content Wfi (before molding) represented by the following formula of the resin supply material 1 of the present invention is preferably 30% or less, preferably 22% or less, and more preferably 15% or less.
- the fiber weight content Wfi exceeds 30%, the resin 2 is poorly impregnated into the base material 2, which may result in a fiber reinforced resin with many voids.
- the fiber weight content Wfi is determined according to JIS K7075 (Test method for fiber content and void ratio of carbon fiber reinforced plastic, 1991).
- the fiber weight content Wfi of the resin supply material 1 is determined by taking out only the resin supply material 1 by polishing or cutting the preform including the resin supply material 1, and JIS K7075 (fiber content of carbon fiber reinforced plastic and It can also be determined according to the cavity ratio test method (1991). When measurement in an uncured state is difficult, a material cured without pressure may be used.
- Wfi Wf1 / (Wf1 + Wr1) ⁇ 100 (%)
- Wf1 Fiber weight in resin feed material (g)
- Wr1 Resin weight in resin feed material (g)
- the fiber volume content Vfi (before molding) represented by the following formula of the resin supply material 1 of the present invention is preferably 0.3% or more, more preferably 0.6% or more, and 1.0% or more. Further preferred. When the fiber volume content Vfi is less than 0.3%, the amount of the resin is too much with respect to the reinforcing fiber, and the resin cannot be supported on the reinforcing fiber, or a large amount of resin may flow outside during molding. is there. Moreover, the fiber volume content Vfi (before molding) represented by the following formula of the resin supply material 1 of the present invention is preferably 20% or less, preferably 15% or less, and more preferably 10% or less.
- the fiber volume content Vfi is determined according to JIS K7075 (Test method for fiber content and void ratio of carbon fiber reinforced plastic, 1991). Further, instead of the method for specifying the fiber volume content Vfi, the thickness T1 (unit: mm, measured value), the basis weight Faw of the reinforcing fiber (unit: g / m 2 , catalog or measured value), the density of the reinforcing fiber
- the fiber volume content Vfi may be obtained by the following formula using ⁇ (unit: g / cm 3 , catalog or measured value).
- Thickness T1 is calculated
- the thickness direction is a direction orthogonal to the contact surface with the base material 2 used for the preform.
- the fiber volume content Vfi of the resin supply material 1 is determined by taking out only the resin supply material 1 by polishing or cutting the preform containing the resin supply material 1, and JIS K7075 (fiber content of carbon fiber reinforced plastic and It can also be determined according to the cavity ratio test method (1991). When measurement in an uncured state is difficult, a material cured without pressure may be used.
- Vfi Vf1 / Vp1 ⁇ 100 (%)
- Vf1 Fiber volume in resin feed material (mm 3 )
- Vp1 Volume of resin feed material (mm 3 )
- Vfi Faw / ⁇ / T1 / 10 (%)
- Faw basis weight of reinforcing fiber (g / m 2 )
- ⁇ Density of reinforcing fiber (g / cm 3 )
- T1 Thickness of resin supply material (mm)
- the resin weight of the resin supply material 1 before and after molding is expressed by the following formula so that the resin flows as little as possible from the resin supply material 1 to the base material 2.
- the change rate P is preferably 0.03 or more, more preferably 0.05 or more, and further preferably 0.08 or more. Further, in order to obtain a fiber reinforced resin with less voids due to the resin flowing from the resin supply material 1 to the base material 2, the change rate P is preferably 0.99 or less, more preferably 0.7 or less, and 5 or less is more preferable.
- the resin weight Wr1 in the resin supply material before molding and the resin weight Wr2 in the resin supply material after molding are obtained in accordance with JIS K7075 (Test method for fiber content and void ratio of carbon fiber reinforced plastic, 1991). It is done. In the case of a preform including the resin supply material 1, only the resin supply material 1 is taken out by polishing or cutting, and conforms to JIS K7075 (Fiber content rate and void ratio test method of carbon fiber reinforced plastic, 1991). Can also be requested.
- Wr2 Resin weight in resin supply material before molding
- Wr2 Resin weight in resin supply material after molding
- the resin supply material 1 of the present invention has a resin supply material before and after molding represented by the following formula:
- the change rate Q of the fiber volume content of 1 is preferably 1.1 or more, more preferably 1.3 or more, and further preferably 1.5 or more. Further, the rate of change Q is preferably 30 or less, more preferably 15 or less, and even more preferably 5 or less so that the resin does not flow out as much as possible and flows efficiently from the resin supply material 1 to the base material 2.
- molding is calculated
- the thickness T1 (unit: mm, measured value), the basis weight Faw of the reinforcing fiber (unit: g / m 2 , catalog or measured value), and the reinforcing fiber
- the fiber volume content Vft may be obtained by the following formula using the density ⁇ (unit: g / cm 3 , catalog or actual measurement value).
- Thickness T1 is calculated
- the thickness direction is a direction orthogonal to the contact surface with the base material 2 used for the preform.
- the fiber volume content Vft of the resin supply material 1 is obtained by taking out only the resin supply material 1 by polishing or cutting the fiber reinforced resin obtained by molding, and JIS K7075 (fiber content and cavity of carbon fiber reinforced plastic) It can also be determined according to the rate test method (1991).
- Vft / Vfi Vfi Fiber volume content before molding (%)
- Vft Fiber volume content after molding (%)
- Vft Faw / ⁇ / T1 / 10 (%)
- Faw basis weight of reinforcing fiber (g / m 2 )
- ⁇ Density of reinforcing fiber (g / cm 3 )
- T1 Thickness of resin supply material (mm)
- the resin supply material 1 of this invention satisfy
- the reinforcing fiber used for the resin supply material 1 may be a continuous fiber used for a unidirectional base material or a woven base material, but a discontinuous fiber is preferable from the viewpoint of resin supply property.
- a web dispersed in a bundle shape or a single fiber shape and having voids impregnated with resin between the fibers is preferable. There are no restrictions on the form or shape of the web. For example, carbon fibers are mixed with organic fibers, organic compounds or inorganic compounds, carbon fibers are bonded with other components, or carbon fibers are bonded to resin components. It may be done.
- a base material in which carbon fibers are sufficiently opened in a form of a nonwoven fabric obtained by a dry method or a wet method, and the carbon fibers are bonded with a binder made of an organic compound can be illustrated as a preferred shape.
- the web made of the above-mentioned reinforcing fiber for use in the resin supply material 1 made of the reinforcing fiber and the resin used for molding the fiber-reinforced resin has a specific fiber length and forms a strong network, has high strength, and will be described later. Thus, it can have a springback characteristic.
- a web having high strength and springback characteristics as a reinforcing fiber constituting the resin supply material 1 of the present invention, it is easy to obtain a high-strength fiber-reinforced resin having excellent resin supply properties (that is, Easy to increase fiber volume content).
- the spring back force can be defined as a web compressive stress (spring back force) at a porosity of 90% based on JIS K6400-2 (hardness and compression deflection, A-1 method, 2012).
- the web compression stress at a porosity of 90% is preferably 5 kPa or more, more preferably 50 kPa or more, and further preferably 100 kPa or more.
- Carbon fiber is preferred as the type of reinforcing fiber, but glass fiber, aramid fiber, metal fiber, etc. may be used.
- the carbon fiber is not particularly limited.
- carbon fibers such as polyacrylonitrile (PAN), pitch, and rayon can be preferably used from the viewpoint of improving mechanical properties and reducing the weight of the fiber reinforced resin. May be used alone or in combination of two or more.
- PAN-based carbon fibers are more preferable from the viewpoint of the balance between strength and elastic modulus of the obtained fiber reinforced resin.
- the single fiber diameter of the reinforcing fiber is preferably 0.5 ⁇ m or more, more preferably 2 ⁇ m or more, and further preferably 4 ⁇ m or more.
- the single fiber diameter of the reinforcing fiber is preferably 20 ⁇ m or less, more preferably 15 ⁇ m or less, and even more preferably 10 ⁇ m or less.
- the strand strength of the reinforcing fiber is preferably 3.0 GPa or more, more preferably 4.0 GPa or more, and further preferably 4.5 GPa or more.
- the strand elastic modulus of the reinforcing fiber is preferably 200 GPa or more, more preferably 220 GPa or more, and further preferably 240 GPa or more. When the strand strength or elastic modulus of the reinforcing fiber is less than 3.0 GPa or less than 200 GPa, respectively, desired properties may not be obtained when a fiber reinforced resin is used.
- the average fiber length of the reinforcing fibers is preferably 0.1 mm or more, more preferably 1 mm or more, and further preferably 2 mm or more. Further, the average fiber length of the reinforcing fibers is preferably 100 mm or less, more preferably 50 mm or less, and further preferably 10 mm or less.
- the average fiber length can be measured by, for example, extracting the reinforcing fibers directly from the reinforcing fiber base material, or dissolving them using a solvent that dissolves only the resin of the prepreg, and filtering the remaining reinforcing fibers to measure by microscopic observation. There is a method to do (dissolution method).
- the resin supply property and the shape following property are lowered, and a molded product having a desired shape may not be obtained.
- the thickness change rate R may be 10 or less, 7 or less are preferable and 4 or less are more preferable.
- t 0 / t 1 exceeds 10
- the handleability of the resin supply material 1 may be lowered.
- a method for measuring the initial thickness and the thickness in a state where the load is removed is not particularly limited, and can be measured by, for example, a micrometer, a caliper, a three-dimensional measuring machine, a laser displacement meter, or microscopic observation.
- the web may be directly observed, or the web may be embedded with a thermosetting resin and observed after the cross section is polished.
- the method for measuring the thickness when a load is applied is not particularly limited.
- the thickness can be measured by applying a load to a web made of reinforcing fibers using a bending tester or a compression tester and reading the displacement.
- the XY plane of the web meaning in the substrate surface; in the present invention, the axis perpendicular to an axis (X axis) in the substrate surface is the Y axis, and the substrate thickness direction (that is, perpendicular to the substrate surface)
- the direction of the fiber is preferably isotropic.
- the average value of the two-dimensional orientation angle of the fibers in the XY plane measured by the measurement method described later is preferably 5 degrees or more, more preferably 20 degrees or more, and further preferably 30 degrees or more. The closer to the ideal angle of 45 degrees, the better. If it is less than 5 degrees, the mechanical properties of the fiber reinforced resin vary greatly depending on the direction, so it may be necessary to consider the laminating direction of the resin supply material.
- the average value of the two-dimensional orientation angle of the fiber in the plane orthogonal to the XY plane of the web, measured by the measurement method described later, is preferably 5 degrees or more, so that the resin supportability is improved, preferably 10 degrees or more. More preferably, 20 degrees or more is more preferable. Further, the average value of the two-dimensional orientation angle of the fiber in the plane orthogonal to the XY plane of the web is preferably 85 degrees or less, more preferably 80 degrees or less, and further preferably 75 degrees or less. If it is less than 5 degrees or exceeds 85 degrees, the fibers become dense and the resin carrying ability may be inferior.
- Mass preferably per unit area of the web of reinforcing fibers used in the present invention, 1 g / m 2 or more, more preferably 10 g / m 2 or more, 30 g / m 2 or more is more preferable. If the mass per unit area is less than 1 g / m 2 , the resin supportability decreases, and the amount of resin necessary for molding may not be pooled. Furthermore, in the process of manufacturing the web and the resin supply material 1, the handleability may be poor and workability may be reduced.
- the fibers in the web made of reinforcing fibers preferably used in the present invention are bonded with a binder.
- the binder is not particularly limited, but polyvinyl alcohol, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polycarbonate resin, styrene resin, polyamide resin, polyester.
- thermoplastic acrylic resin thermoplastic polyester resin
- thermoplastic polyamideimide resin acrylonitrile-butadiene copolymer
- Polymers such as polymers, styrene-butadiene copolymers, acrylonitrile-styrene-butadiene copolymers, urethane resins, melamine resins, urea resins, thermosetting type Le resins, phenol resins, epoxy resins, thermosetting resins such as thermosetting polyesters is preferably used.
- a resin having a group is preferably used.
- These binders may be used alone or in combination of two or more.
- the adhesion amount of the binder is preferably 0.01% or more, more preferably 0.1% or more, and further preferably 1% or more. Further, the adhesion amount of the binder is preferably 20% or less, more preferably 15% or less, and further preferably 10% or less.
- the drying process may take time or the resin impregnation property may be lowered.
- the adhesion amount of the binder is less than 0.01%, when a web made of reinforcing fibers is used in the present invention, it is difficult to maintain the form and the handling property may be deteriorated.
- the measuring method of the adhesion amount of a binder is mentioned later.
- the resin used for the resin supply material 1 of the present invention will be described.
- the viscosity at the time of impregnation of the resin used in the present invention is preferably 1000 Pa ⁇ s or less, more preferably 100 Pa ⁇ s or less, and further preferably 10 Pa ⁇ s or less. When it exceeds 1000 Pa ⁇ s, there is a concern that voids are generated in the obtained fiber-reinforced resin because the base material 2 described later is not sufficiently impregnated with the resin.
- the type of resin used in the present invention is not particularly limited, and any of a thermosetting resin and a thermoplastic resin can be used.
- the resin is a thermosetting resin
- the thermosetting resin is cured by heating at the time of molding and, if necessary, by further heating to a temperature at which the thermosetting resin is cured after molding. Is obtained.
- the resin is a thermoplastic resin
- a fiber-reinforced resin can be obtained by cooling and solidifying the resin melted by heating during molding.
- the thermosetting resin epoxy resin, vinyl ester resin, phenol resin, thermosetting polyimide resin, polyurethane resin, urea resin, melamine resin, bismaleimide resin and the like are preferably used.
- thermoplastic resins polypropylene resin, polyethylene resin, polycarbonate resin, polyamide resin, polyester resin, polyarylene sulfide resin, polyphenylene sulfide resin, polyether ketone, polyether ether ketone resin, polyether ketone ketone resin, polyether sulfone resin
- Polyimide resin, polyamideimide resin, polyetherimide resin, and polysulfone resin are preferably used, and a cyclic oligomer that is a precursor of any of these resins is also preferably used.
- the substrate 2 used in the preform of the present invention is a fiber substrate made of reinforcing fibers, and is at least one selected from a woven fabric substrate made of reinforcing fibers, a unidirectional substrate, and a mat substrate.
- a non-woven fabric is preferably used.
- the continuous fiber means a reinforcing fiber in which the reinforcing fiber bundles are arranged in a continuous state without cutting the reinforcing fiber into a short fiber state.
- the form and arrangement of the reinforcing fibers used for the base material 2 can be appropriately selected from the forms of continuous fibers such as long fibers, woven fabrics, tows, and rovings that are aligned in one direction.
- the number of filaments in one fiber bundle used for the substrate 2 is preferably 500 or more, more preferably 1500 or more, and further preferably 2500 or more.
- the number of filaments in one fiber bundle is preferably 150,000 or less, more preferably 100,000 or less, and even more preferably 70000 or less.
- a fiber reinforced resin having high mechanical properties it is preferable to use a woven fabric base material or a unidirectional base material made of continuous reinforcing fibers for the base material 2, but the impregnation rate of the resin is increased to produce a fiber reinforced resin.
- a mat substrate made of discontinuous fibers it is preferable to use a mat substrate made of discontinuous fibers as the substrate 2.
- Examples of a method for producing a fiber reinforced resin using the resin supply material 1 of the present invention include the following methods. That is, first, a preform 3 including a resin supply material 1 and at least one kind of base material 2 selected from a sheet-like base material, a cloth-like base material, and a porous base material is prepared and set on a mold. . After softening the resin supply material 1 on a high-temperature mold, the resin is supplied to the substrate 2 by pressurization.
- the pressing method is preferably press pressure molding or vacuum pressure molding.
- the resin is a thermosetting resin, the temperature at the time of resin supply and the time of curing may be the same or different.
- the temperature at the time of resin supply is preferably higher by 10 ° C. than the melting point of the resin.
- the solidifying temperature is preferably 10 ° C. or more lower than the melting point of the resin, more preferably 30 ° C. or more, and further preferably 50 ° C. or more.
- the mold may be a double-sided mold such as a closed mold made of a rigid body or a single-sided mold.
- the preform 3 can also be installed between the flexible film and the rigid open mold (in this case, as described above, the space between the flexible film and the rigid open mold is in a reduced pressure state from the outside. Therefore, the preform 3 is in a pressurized state).
- the average value of the two-dimensional fiber orientation angle on the XY plane is measured by the following procedures I and II.
- the X axis, the Y axis, and the Z axis are orthogonal to each other, the XY plane is in the substrate surface, and the Z axis is the substrate thickness direction.
- the average value of the two-dimensional orientation angles with all the reinforcing fiber single fibers intersecting with the reinforcing fiber single fibers randomly selected in the XY plane is measured. When there are a large number of reinforcing fiber single fibers that intersect the reinforcing fiber single fibers, an average value obtained by randomly selecting and measuring 20 reinforcing fiber single fibers may be substituted.
- II. The measurement of I is repeated a total of 5 times while paying attention to another single reinforcing fiber, and the average value is calculated as the average value of the two-dimensional orientation angle of the fibers.
- the method for measuring the average value of the two-dimensional orientation angle of fibers from the prepreg is not particularly limited, and examples thereof include a method of observing the orientation of reinforcing fibers from the surface of the prepreg.
- the surface of the prepreg is polished to expose the fibers, which makes it easier to observe the reinforcing fibers.
- the method of observing the orientation of a reinforced fiber using transmitted light for a prepreg can be illustrated. In this case, it is preferable to slice the prepreg thinly because it becomes easier to observe the reinforcing fibers.
- a method of photographing the orientation image of the reinforcing fiber by observing the prepreg through X-ray CT can be exemplified. In the case of reinforcing fibers with high X-ray permeability, it is easier to observe reinforcing fibers by mixing tracer fibers with reinforcing fibers or applying tracer chemicals to reinforcing fibers. preferable.
- a method of observing the orientation of the reinforcing fiber after removing the resin so as not to destroy the structure of the reinforcing fiber can be exemplified.
- a prepreg is sandwiched between two stainless meshes, fixed with screws so that the prepreg does not move, the resin component is burned off, and the resulting reinforcing fiber substrate is observed and measured with an optical microscope or an electron microscope. be able to.
- the fiber two-dimensional orientation angle of a reinforcing fiber monofilament randomly selected on a plane orthogonal to the XY plane is measured.
- the two-dimensional orientation angle of the fiber is 0 degree when parallel to the Z axis and 90 degrees when perpendicular to the Z axis. Therefore, the range of the fiber two-dimensional orientation angle is 0 to 90 degrees.
- II. The above measurement of I is carried out on a total of 50 reinforcing fiber monofilaments, and the average value is calculated as the average value of the two-dimensional orientation angles of the fibers in the plane orthogonal to the XY plane.
- the method for measuring the average value of the fiber inclination angle from the prepreg is not particularly limited, and for example, a method of observing the orientation of the reinforcing fiber from the YZ plane (ZX plane) of the prepreg can be exemplified. In this case, polishing the prepreg cross section to expose the fibers is preferable because the reinforcing fibers can be more easily observed. Moreover, the method of observing the orientation of a reinforced fiber using transmitted light for a prepreg can be illustrated. In this case, it is preferable to slice the prepreg thinly because it becomes easier to observe the reinforcing fibers.
- a method of photographing the orientation image of the reinforcing fiber by observing the prepreg through X-ray CT can be exemplified.
- reinforcing fibers with high X-ray permeability it is easier to observe reinforcing fibers by mixing tracer fibers with reinforcing fibers or applying tracer chemicals to reinforcing fibers. preferable.
- Binder adhesion amount (%) (W 1 ⁇ W 2 ) / W 1 ⁇ 100
- Reference example 1 reinforcementd fiber (carbon fiber)
- Spinning, baking treatment and surface oxidation treatment were carried out from a PAN-based copolymer to obtain continuous carbon fibers having a total number of 12,000 single fibers.
- the characteristics of this continuous carbon fiber were as follows.
- Reference example 2 (resin (epoxy resin (1)) 40 parts by mass of “jER (registered trademark)” 1007 (manufactured by Mitsubishi Chemical Corporation), 20 parts by mass of “jER (registered trademark)” 630 (manufactured by Mitsubishi Chemical Corporation), “Epiclon (registered trademark)” 830 40 parts by mass (manufactured by DIC Corporation), and DICY7 (manufactured by Mitsubishi Chemical Corporation) as a curing agent, an amount that gives 0.9 equivalent of active hydrogen groups to the epoxy groups of all epoxy resin components, a curing accelerator
- an epoxy resin (1) was prepared using 2 parts by mass of DCMU99 (manufactured by Hodogaya Chemical Co., Ltd.).
- Reference example 3 (resin (epoxy resin (2))) 6 parts by mass of “jER (registered trademark)” 630 (manufactured by Mitsubishi Chemical Corporation), 19 parts by mass of “EPON (registered trademark)” 825 (manufactured by Mitsubishi Chemical Corporation), diglycidylaniline (Nippon Kayaku ( Co., Ltd.) 15 parts by mass, “Kane Ace (registered trademark)” MX-416 (manufactured by Kaneka Corporation) 60 parts by mass, “jER Cure (registered trademark)” W 31 parts by mass as a curing agent, curing acceleration Epoxy resin (2) was prepared using 1 part by mass of DIC-TBC (manufactured by DIC Corporation) as an agent.
- DIC-TBC manufactured by DIC Corporation
- Reference example 4 epoxy resin film
- the epoxy resin (1) prepared in Reference Example 2 was applied onto release paper using a reverse roll coater, and resin films having masses per unit area of 37, 74, and 100 g / m 2 were produced.
- Reference Example 5 carbon fiber web (1)
- the carbon fiber obtained in Reference Example 1 was cut to a predetermined length with a cartridge cutter to obtain chopped carbon fiber.
- a dispersion liquid having a concentration of 0.1% by mass composed of water and a surfactant (polyoxyethylene lauryl ether (trade name), manufactured by Nacalai Tex Co., Ltd.) is prepared, and the dispersion liquid and the chopped carbon fiber are used.
- a papermaking substrate was produced with a papermaking substrate production apparatus.
- the manufacturing apparatus includes a cylindrical container having a diameter of 1000 mm having an opening cock at the bottom of the container as a dispersion tank, and a linear transport section (inclination angle of 30 degrees) that connects the dispersion tank and the papermaking tank.
- a stirrer is attached to the opening on the upper surface of the dispersion tank, and chopped carbon fiber and dispersion liquid (dispersion medium) can be input from the opening.
- the papermaking tank is a tank provided with a mesh conveyor having a papermaking surface having a width of 500 mm at the bottom, and a conveyor capable of transporting a carbon fiber substrate (papermaking substrate) is connected to the mesh conveyor.
- the mass per unit area was adjusted by adjusting the carbon fiber concentration in the dispersion.
- About 5% by mass of a polyvinyl alcohol aqueous solution (Kuraray Poval, Kuraray Co., Ltd.) as a binder was attached to the paper-made carbon fiber substrate and dried in a drying oven at 140 ° C.
- the average fiber length is 5.8 mm
- the average value of the two-dimensional orientation angle of the fiber in the XY plane is 47.3 °
- the average value of the two-dimensional orientation angle of the fiber in the plane orthogonal to the XY plane is 80.7 °. there were.
- Reference Example 6 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the basis weight of the carbon fiber was 100 g / m 2 , the fiber volume content was 3.0%, and the fiber weight content was 5.0%.
- An impregnation test was performed using the obtained resin supply material and 15 dry fabrics (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ). The procedure is as follows.
- the obtained resin supply material (size: 10 ⁇ 10 cm 2 ) is placed on 15 sheets of dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes.
- the resin spread area of the resin supply material arrangement layer was measured and found to be 200 cm 2 . Further, the impregnation distance was about 13 layers including the resin film arrangement layer.
- Reference Example 7 The carbon fiber web (1) obtained in Reference Example 5 (weight per unit of 1100 g / m 2 ) is sandwiched by one layer of dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, weight per unit of weight 198 g / m 2 ).
- the epoxy resin (2) prepared in 3 was impregnated at 40 ° C. under vacuum and 2 MPa pressure, and then heated at 3 ° C./min and held at 150 ° C. for 40 minutes to form a composite. When a tensile test was carried out based on JIS 7164 (2005), the composite strength was 315.3 MPa.
- Reference Example 8 An impregnation test was carried out using the epoxy resin film obtained in Reference Example 4 and 15 dry fabrics (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ). The procedure is as follows.
- the epoxy resin film (size: 10 ⁇ 10 cm 2 ) 1440 g / m 2 obtained in Reference Example 4 was used as a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ) 15 Place on the sheet.
- the laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes.
- Reference Example 9 Melamine resin foam (made by BASF Corp., Basotect UF grade, basis weight 670 g / m 2 ) is sandwiched by one layer of dry woven fabric (cloth made by Toray Industries, Ltd., product number: CO6343B, plain weave, basis weight 198 g / m 2 ), reference The epoxy resin (2) prepared in Example 3 was impregnated at 40 ° C. under vacuum and 2 MPa pressure, and then heated at 3 ° C./min and held at 150 ° C. for 40 minutes to form a composite. When a tensile test was carried out according to JIS 7164 (2005), the composite strength was 42.5 MPa.
- Example 1 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 4.3%
- the fiber weight content was 6.3%
- Example 2 A flat plate was prepared using the resin supply material obtained in Example 1 and a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, carbon fiber basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 1 Two layers of dry fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 1. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers is 13.8%, and the fiber volume content of the woven fabric layer is 68. 1%.
- the resin weight change rate P in the resin supply material before and after molding was 0.28, and the change rate Q of the fiber volume content was 3.2.
- the obtained flat plate was cross-sectionally observed, but no void was confirmed inside.
- the presence or absence of voids was determined by the presence or absence of voids having a diameter of 5 ⁇ m or more in the microscope observation image.
- Example 3 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 6.2%, and the fiber weight content was 9.1%.
- Example 4 A flat plate was prepared using the resin supply material obtained in Example 3 and a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 3 Two layers of dry woven fabrics are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 3. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers was 16.1%, and the fiber volume content of the woven fabric layer was 61. It was 6%.
- the resin weight change rate P in the resin supply material before and after molding was 0.38, and the fiber volume content change rate Q was 2.6.
- the obtained flat plate was cross-sectionally observed, but no void was confirmed inside.
- Example 5 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 7.7%, and the fiber weight content was 11.1%.
- Example 6 A flat plate was prepared using the resin supply material obtained in Example 5 and a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ). The molding process is as follows.
- Example 5 Two layers of dry fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 5. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers is 16.4%
- the fiber volume content of the woven fabric layer is 63. 7%.
- the resin weight change rate P in the resin supply material before and after molding was 0.43
- the change rate Q of the fiber volume content was 2.1. The obtained flat plate was cross-sectionally observed, but no void was confirmed inside.
- Example 7 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 11.8%, and the fiber weight content was 16.7%.
- Example 8 A flat plate was prepared using the resin supply material obtained in Example 7 and a dry woven fabric (cloth manufactured by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ). The molding process is as follows.
- Example 7 Two layers of dry fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 7. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers is 17.7%, and the fiber volume content of the fabric layer is 68. 2%.
- the resin weight change rate P in the resin supply material before and after molding was 0.62, and the fiber volume content change rate Q was 1.5.
- the obtained flat plate was cross-sectionally observed, but no void was confirmed inside.
- Example 9 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 10.4%, and the fiber weight content was 14.5%.
- Example 10 A flat plate was prepared using the resin supply material obtained in Example 9 and a dry woven fabric (Toray Cross, product number: CO6343B, plain weave, basis weight 198 g / m 2 ). The molding process is as follows.
- Example 9 Two layers of dry woven fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 9. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer), calculated from the thickness of each layer and the basis weight of the reinforcing fibers, was 16.2%, and the fiber volume content of the fabric layer was 67. 1%.
- the resin weight change rate P in the resin supply material before and after molding was 0.60, and the change rate Q of the fiber volume content was 1.6.
- the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- the void ratio was calculated as an area ratio occupied by voids in an observation image of a microscope using area analysis software for each color.
- Example 11 The carbon fiber web (1) obtained in Reference Example 5 was impregnated with the epoxy resin (1) prepared in Reference Example 2 to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 11.5%, and the fiber weight content was 16.0%.
- Example 12 A flat plate was prepared using the resin supply material obtained in Example 11 and a dry woven fabric (cloth produced by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 11 Two layers of the dry woven fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 11. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer), calculated from the thickness of each layer and the basis weight of the reinforcing fibers, was 16.9%, and the fiber volume content of the woven fabric layer was 62. 7%.
- the resin weight change rate P in the resin supply material before and after molding was 0.64, and the fiber volume content change rate Q was 1.5.
- Example 13 Between the laminates of the carbon fiber web (1) obtained in Reference Example 5 (carbon fiber basis weight: 100 g / m 2 , size: 13.8 ⁇ 13.8 cm 2 ), the epoxy resin obtained in Reference Example 4 A film (size: 13.8 ⁇ 13.8 cm 2 ) was placed at 3000 g / m 2 to prepare a resin supply material. As shown in Table 1 (a), the fiber volume content was 0.6%, and the fiber weight content was 3.2%.
- Example 14 A flat plate was prepared using the resin supply material obtained in Example 13 and a dry woven fabric (cloth produced by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 13 (2) Two layers of dry woven fabrics are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 13. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers was 17.1%, and the fiber volume content of the woven fabric layer was 62. 1%.
- the resin weight change rate P in the resin supply material before and after molding was 0.11, and the fiber volume content change rate Q was 28.5.
- the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- Example 15 Between the laminates of the carbon fiber web (1) obtained in Reference Example 5 (carbon fiber basis weight: 100 g / m 2 , size: 13.8 ⁇ 13.8 cm 2 ), the epoxy resin obtained in Reference Example 4 A film (size: 13.8 ⁇ 13.8 cm 2 ) was placed at 1000 g / m 2 to prepare a resin supply material. As shown in Table 1 (a), the fiber volume content was 1.1%, and the fiber weight content was 9.1%.
- Example 16 A flat plate was prepared using the resin supply material obtained in Example 15 and a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 15 Two layers of dry fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 15. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer), calculated from the thickness of each layer and the basis weight of the reinforcing fibers, was 16.4%, and the fiber volume content of the fabric layer was 65. It was 5%. Further, the resin weight change rate P in the resin supply material before and after molding was 0.34, and the change rate Q of the fiber volume content was 14.9. When the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- Example 17 Between the laminates of the carbon fiber web (1) obtained in Reference Example 5 (carbon fiber basis weight: 500 g / m 2 , size: 13.8 ⁇ 13.8 cm 2 ), the epoxy resin obtained in Reference Example 4 A film (size: 13.8 ⁇ 13.8 cm 2 ) was placed at 1900 g / m 2 to prepare a resin supply material. As shown in Table 1 (a), the fiber volume content was 12.5%, and the fiber weight content was 20.8%.
- Example 18 A flat plate was prepared using the resin supply material obtained in Example 17 and a dry woven fabric (cloth made by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 17 Two layers of dry woven fabric are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 17. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer), calculated from the thickness of each layer and the basis weight of the reinforcing fibers, was 16.8%, and the fiber volume content of the fabric layer was 64. 1%.
- the resin weight change rate P in the resin supply material before and after molding was 0.87, and the fiber volume content change rate Q was 1.3.
- the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- Example 19 Between the laminations of the carbon fiber web (1) obtained in Reference Example 5 (carbon fiber basis weight: 1200 g / m 2 , size: 13.8 ⁇ 13.8 cm 2 ), the epoxy resin obtained in Reference Example 4 A film (size: 13.8 ⁇ 13.8 cm 2 ) was placed at 4300 g / m 2 to prepare a resin supply material. As shown in Table 1 (a), the fiber volume content was 14.5%, and the fiber weight content was 21.8%.
- Example 20 A flat plate was prepared using the resin supply material obtained in Example 19 and a dry woven fabric (cloth produced by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 19 Two layers of dry woven fabrics are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 19. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers is 16.1%, and the fiber volume content of the woven fabric layer is 66. 3%.
- the resin weight change rate P in the resin supply material before and after molding was 0.97, and the fiber volume content change rate Q was 1.1.
- the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- Example 21 60 pieces of the carbon fiber web (1) obtained in Reference Example 5 were cut to a width of 5 mm, and rotated and arranged so that the XY plane became the ZX plane. A web having a basis weight of 220 g / m 2 was produced. The average value of the two-dimensional orientation angle of the XY plane is 8.7 °, and the average value of the fiber two-dimensional orientation angle of the plane orthogonal to the XY plane is 9.1 ° (YZ plane), 45.1. ° (ZX plane). The obtained web was impregnated with the epoxy resin (1) prepared in Reference Example 2 to prepare a resin supply material. The impregnation process is as follows.
- the fiber volume content was 8.8%
- the fiber weight content was 12.8%.
- Example 22 A flat plate was prepared using the resin supply material obtained in Example 21 and a dry woven fabric (cloth produced by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- Example 21 Two layers of dry woven fabrics are arranged on the front and back of the resin supply material (size: 13.8 ⁇ 13.8 cm 2 ) obtained in Example 21. (2) The laminated body of (1) is preheated with a press at zero pressure and 70 ° C. for about 10 minutes. (3) Pressurize at 1 MPa. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the fiber volume content of the reinforcing fiber web layer (resin supply layer) calculated from the thickness of each layer and the basis weight of the reinforcing fibers is 17.2%, and the fiber volume content of the woven fabric layer is 63. It was 5%.
- the resin weight change rate P in the resin supply material before and after molding was 0.46, and the change rate Q of the fiber volume content was 2.0.
- the cross section of the obtained flat plate was observed, voids were slightly confirmed, and the void ratio was less than 5%.
- Example 23 As shown in Table 2, in accordance with JIS K6400-2 (Hardness and compression deflection A-1 method, 2012), strengthening for use in the resin supply material obtained in Reference Example 5 at a porosity of 90% It was 200 kPa when the compressive stress (spring back force) of the web used as a fiber was measured.
- the initial thickness t 0 was 51 mm
- the thickness t 1 at 0.1 MPa was 18 mm
- t 0 / t 1 was 2.8.
- Comparative Example 2 The carbon fiber bundle obtained in Reference Example 1 was cut to a length of 25 mm with a cartridge cutter to produce a resin supply material.
- the impregnation process is as follows.
- the fiber volume content was 21.6%, and the fiber weight content was 33.3%.
- Comparative Example 3 A flat plate was prepared using the resin supply material obtained in Comparative Example 2 and a dry woven fabric (cloth manufactured by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- the fiber volume content was 33.0%, and the fiber weight content was 49.7%.
- Comparative Example 5 A flat plate was prepared using the resin supply material obtained in Comparative Example 4 and a dry woven fabric (cloth produced by Toray Industries, Inc., product number: CO6343B, plain weave, basis weight 198 g / m 2 ).
- the molding process is as follows.
- the melamine resin foam is different from the reinforcing fiber to be used for the resin supply material when the porosity is 90%. It was 210 kPa when the compressive stress (spring back force) of the body (BASF, Basotect UF grade) was measured. The initial thickness t 0 was 50 mm, the thickness t 1 at 0.1 MPa was 4 mm, and t 0 / t 1 was 12.5.
- the present invention is a resin supply material composed of a film made of a thermoplastic resin and a thermosetting resin.
- the resin supply material 1 is prepared by laminating the resin supply material 1 with a base material 2 to produce a preform 3, and heating and pressurizing the preform 3 in a closed space, for example.
- a thermosetting resin from the supply material 1 to the base material 2
- the mold may be a double-sided mold such as a closed mold made of a rigid body or a single-sided mold.
- the preform 3 can be placed between the flexible film and the rigid open mold (in this case, the space between the flexible film and the rigid open mold is in a reduced pressure state from the outside, The preform 3 is in a pressurized state).
- the resin supply material 1 of the present invention is preferably in the form of a sheet composed of a film made of a thermoplastic resin and a thermosetting resin.
- the sheet thickness is preferably 0.1 mm or more, and more preferably 0.5 mm or more from the viewpoint of resin supply properties and mechanical properties. Further, from the viewpoint of handleability and formability, the sheet thickness is preferably 100 mm or less, more preferably 60 mm or less, and even more preferably 30 mm or less.
- the method for measuring the sheet thickness is not particularly limited, but can be measured by, for example, a micrometer, a caliper, a three-dimensional measuring machine, or a laser displacement meter.
- the value X obtained by dividing the tensile load F at the yield point measured by the tensile test (JIS K 7127 (1999)) in the present invention by the width W of the test piece is 1 N / mm or more at 25 ° C., Preferably it is 2 N / mm or more.
- the resin supply material 1 can be easily handled without being broken during transport or lamination.
- the value X is less than 1 N / mm, preferably less than 0.5 N / mm.
- the temperature T is a temperature at which the viscosity of the thermosetting resin is minimized when the thermosetting resin is heated from 30 ° C. to 1.5 ° C./min.
- the lowest temperature is set as the temperature T.
- thermosetting resin is cured through a melting process at an elevated temperature.
- the viscosity of the thermosetting resin continuously decreases during the melting process and starts to increase due to the curing reaction.
- the impregnation property with respect to the base material 2 is improved as the viscosity of the thermosetting resin is lower. Accordingly, when the thermosetting resin is supplied to the base material 2 when the viscosity of the thermosetting resin is minimized, it is considered that the impregnation property is the best.
- the thermosetting resin cannot be supplied to the base material 2 only when the viscosity of the thermosetting resin becomes the minimum, and can be supplied from the start of the temperature rise to the initial stage of the curing reaction. After the curing reaction proceeds and the viscosity of the thermosetting resin is remarkably improved, it becomes difficult to supply the thermosetting resin.
- the coating film has a value X of less than 1 N / mm at a temperature at which the viscosity of the thermosetting resin starts to increase due to the curing reaction when the temperature of the thermosetting resin is raised, that is, at temperature T. Since the value X tends to be smaller as the temperature is higher, the coating is broken at a temperature equal to or lower than the temperature T at the time of molding, and the thermosetting resin can be supplied. Therefore, a process such as making a hole in the coating before molding is not required, and a molding method with excellent processability is possible.
- the coating usually forms a closed space.
- the region where the thermosetting resin is present can be a closed space separating the coating from the outside world, so there is no leakage of uncured resin,
- a low-viscosity thermosetting resin can also be used.
- the closed space means a space surrounded by a film that does not transmit thermosetting resin at 25 ° C. under atmospheric pressure, and the thermosetting resin transmits through the film forming the space at 25 ° C. under atmospheric pressure. It does not matter if there are enough holes.
- the form of the coating is not limited, it is preferably in the form of a sheet such as a film or a porous film.
- a porous film having a pore size through which the thermosetting resin does not permeate is preferably used in accordance with the viscosity at 25 ° C. of the thermosetting resin to be used.
- the thickness of the coating is preferably 1 ⁇ m to 300 ⁇ m, more preferably 1 ⁇ m to 150 ⁇ m, and particularly preferably 1 ⁇ m to 100 ⁇ m.
- the thickness of the coating is preferably 1 ⁇ m to 300 ⁇ m, more preferably 1 ⁇ m to 150 ⁇ m, and particularly preferably 1 ⁇ m to 100 ⁇ m.
- the method for measuring the thickness of the coating is not particularly limited, but can be measured by, for example, micrometer or microscopic observation.
- thermosetting resin preferably occupies 90% or more of the closed space, more preferably 95% or more, and particularly preferably 98% or more.
- the temperature at which the viscosity of a thermosetting resin such as an epoxy resin starts to increase in the temperature rising process is 100 ° C. or more and 200 ° C. or less. Therefore, the melting point of the thermoplastic resin is preferably 100 ° C. or higher and 200 ° C. or lower.
- the melting point of the thermoplastic resin is preferably 100 ° C. or higher and 200 ° C. or lower.
- the main component of the thermoplastic resin may be an ordinary thermoplastic resin and is not particularly limited, but polyolefin, polyamide, and polyester are preferably used from the viewpoint of moldability and flexibility.
- a main component here means the component which is 70 mass% or more in the ratio occupied to a film.
- the thermoplastic resin can further contain additives such as fillers and plasticizers.
- an inorganic filler and an organic filler that does not melt at the temperature T are preferably used, and examples thereof include mica, glass beads, silica, aluminum hydroxide, titanium oxide, and alumina.
- the filler aspect ratio is the ratio of the major axis length to the minor axis length of the filler, and can be determined by the following method.
- a sample in which a filler is dispersed in a liquid such as water and cast on a slide glass is observed with a laser microscope (for example, VK-9500 manufactured by KEYENCE), and the longest length of any filler is measured. Length.
- the difference in depth of focus between the upper surface of the slide glass and the upper surface of the filler is measured to obtain a short axis length.
- a value obtained by dividing the measured major axis length by the minor axis length is obtained.
- values are obtained for a total of 100 samples, and this average is taken as the aspect ratio.
- the value X due to the temperature T in the coating may be reduced.
- the viscosity of the thermosetting resin at a temperature 20 ° C. lower than the melting point of the thermoplastic resin is 100 Pa ⁇ s or less. preferable. By setting the viscosity to 100 Pa ⁇ s or less, the resin is quickly supplied to the substrate 2.
- the viscosity of the thermosetting resin at 40 ° C. is preferably 0.01 Pa ⁇ s to 4000 Pa ⁇ s. By setting it as such a range, the followability to a type
- thermosetting resin used in the present invention is not particularly limited, but is preferably an epoxy resin, vinyl ester resin, phenol resin, thermosetting polyimide resin, polyurethane resin, urea resin, melamine resin, bismaleimide resin, and the like. Used. In addition to a single epoxy resin, a copolymer of epoxy resin and a thermosetting resin, a modified product, and a resin blended with two or more types can also be used.
- Examples of the method for producing the resin supply material 1 of the present invention include the following methods.
- a bag with three sides closed is manufactured by joining one side of a thermoplastic resin film formed into a tube shape by an inflation method.
- two thermoplastic resin films are stacked, the opening for the thermosetting resin is left, the rest is joined, and the one thermoplastic resin film is folded and the opening for the thermosetting resin is added.
- a bag can be manufactured by a method of joining the rest while leaving the mark.
- the resin supply material 1 can be manufactured by putting a thermosetting resin into the obtained bag and joining the open mouth.
- the thermosetting resin can be formed into a film, it can also be produced by sandwiching the film-like thermosetting resin with a thermoplastic resin film and joining the ends.
- the method for bonding the film is not particularly limited, and examples thereof include a method using an adhesive, heat sealing, impulse sealing, high frequency bonding, and ultrasonic bonding.
- the preform of the present invention includes the resin supply material 1 and the base material 2 described above.
- the base material 2 is a state which does not contain matrix resin, ie, a dry state.
- the preform means a laminated body in which the resin supply material 1 and the base material 2 are laminated and integrated, and a predetermined number of the resin supply materials 1 are laminated and the outermost layer of the laminated body is integrated.
- Examples include a sandwich laminate sandwiched between the substrates 2, an alternate laminate in which the resin supply material 1 and the substrate 2 are alternately laminated, and combinations thereof. It is preferable to form a preform in advance because the base material 2 can be impregnated with the thermosetting resin quickly and more uniformly in the production process of the fiber reinforced resin.
- the base material 2 used for the preform is a fiber base material made of reinforcing fibers, and a woven base material, unidirectional base material, and mat base material made of reinforcing fibers are preferable.
- a fabric base fabric made of continuous fibers, alone or laminated, or a fabric base fabric stitched and integrated with stitch yarn, or a fiber structure such as a three-dimensional fabric or a braid, or a discontinuous fiber A non-woven fabric is preferably used.
- the continuous reinforcing fiber means a carbon fiber in which carbon fiber bundles are arranged in a continuous state without cutting the reinforcing fiber into a short fiber state.
- a fiber reinforced resin having high mechanical properties it is preferable to use a woven fabric base material or a unidirectional base material made of continuous reinforcing fibers for the base material 2.
- a mat substrate made of discontinuous fibers it is preferable to use a mat substrate made of discontinuous fibers as the substrate 2.
- the form and arrangement of the continuous fibers used for the substrate 2 in the present invention can be appropriately selected from forms such as long fibers arranged in one direction, woven fabric, tow, and roving.
- the number of filaments in one fiber bundle of continuous fibers used for the substrate 2 is preferably 500 or more, more preferably 1500 or more, and even more preferably 2500 or more.
- the number of filaments in one fiber bundle is preferably 150,000 or less, more preferably 100,000 or less, and even more preferably 70000 or less.
- thermosetting resin is supplied from the resin supply material 1 to the substrate 2 and molded.
- the method of doing is mentioned. That is, first, a preform 3 including a resin supply material 1 and a base material 2 is produced and set on a mold. After softening the resin supply material 1 on a high-temperature mold, the thermosetting resin is supplied to the substrate 2 by pressurization.
- the pressing method is preferably press pressure molding or vacuum pressure molding. The temperature at the time of resin supply and at the time of curing may be the same or different.
- the mold may be a double-sided mold such as a closed mold made of a rigid body or a single-sided mold.
- the preform 3 can also be installed between the flexible film and the rigid open mold (in this case, as described above, the space between the flexible film and the rigid open mold is in a reduced pressure state from the outside. Therefore, the preform 3 is in a pressurized state).
- Thermoplastic resin (1) 1700J (manufactured by Prime Polymer Co., Ltd., high density polyethylene pellet, melting point 135 ° C.)
- Thermoplastic resin (2) CM4000 (manufactured by Toray Industries, Inc., terpolymer polyamide resin (polyamide 6/66/610) pellet, melting point 150 ° C.)
- Thermoplastic resin (3) J106MG (manufactured by Prime Polymer, polypropylene pellets, melting point 165 ° C.)
- Epoxy resin (1) 50 parts by mass of “Araldide (registered trademark)” MY0600 (manufactured by Huntsman Japan Co., Ltd.), 50 parts by mass of “EPICLON (registered trademark)” 830 (manufactured by DIC), bis (4-aminophenyl) sulfone (Tokyo Kasei) Kogyo Co., Ltd.) 40 parts by mass, 3-hydroxy-2-naphthoic acid hydrazide (Otsuka Chemical Co., Ltd.) 5 parts by mass, Sumika Excel 5003P (Sumitomo Chemical Co., Ltd.) 30 parts by mass, and epoxy resin (1) was prepared.
- the temperature T at which the viscosity of the epoxy resin (1) was minimized was 138 ° C., and the viscosity at 40 ° C. was 2380 Pa ⁇ s.
- the resulting epoxy resin (1) was applied onto release paper using a reverse roll coater, a mass per unit area to produce an epoxy resin film respectively 100g / m 2, 37g / m 2. At this time, the mass per unit area of the film was changed by laminating these films according to the purpose.
- Epoxy resin (2) 6 parts by mass of “jER (registered trademark)” 630 (manufactured by Mitsubishi Chemical Corporation), 19 parts by mass of “EPON (registered trademark)” 825 (manufactured by Mitsubishi Chemical Corporation), diglycidylaniline (manufactured by Nippon Kayaku) ), 15 parts by weight of “Kane Ace (registered trademark)” MX-416 (manufactured by Kaneka), 31 parts by weight of “jER Cure (registered trademark)” W as a curing agent, and DIC-TBC (as a curing accelerator) Epoxy resin (2) was prepared using 1 part by mass of DIC. The temperature T at which the viscosity of the epoxy resin (2) was minimized was 110 ° C., and the viscosity at 40 ° C. was 5.6 Pa ⁇ s.
- Carbon fiber fabric (1) CO6343B (manufactured by Toray Industries, plain weave, basis weight 198 g / m 2 )
- Example 1 Using a pellet of the thermoplastic resin (1), a tube-like film having a width of 10 cm was produced by an inflation film-forming method, and cut into a length of 12 cm. The film thickness was 87 ⁇ m. One end of the tube-like film mouth was heat-sealed at a location 1 cm from the end to form a bag. 6.74 g of the epoxy resin (2) was put in the obtained bag, and the other mouth was heat-sealed at a location 1 cm from the end to obtain a resin supply material (1).
- the resin supply material (1) was in the form of a sheet, and its thickness was 0.74 mm.
- Example 2 Using a pellet of the thermoplastic resin (3), a tube-like film having a width of 10 cm was produced by an inflation film forming method, and cut into a length of 12 cm. The film thickness was 93 ⁇ m. One end of the tube-like film mouth was heat-sealed at a location 1 cm from the end to form a bag. 6.74 g of the epoxy resin (2) was put into the obtained bag, and the other mouth was heat-sealed at a location 1 cm from the end to obtain a resin supply material (2). The resin supply material (2) was a sheet and had a thickness of 0.75 mm.
- Example 3 Using a pellet of the thermoplastic resin (1), a tube-like film having a width of 10 cm was produced by an inflation film-forming method, and cut into a length of 12 cm. The film thickness was 87 ⁇ m. One end of the tube-like film mouth was heat-sealed at a location 1 cm from the end to form a bag. An epoxy resin (1) (674 g / m 2 ) having a size of 10 cm ⁇ 10 cm is put into the obtained bag, and the other mouth is heat-sealed at a location 1 cm from the end, thereby obtaining a resin supply material (3). It was. The resin supply material (3) was in the form of a sheet, and its thickness was 0.74 mm.
- Example 4 A film was produced with a press using pellets of the thermoplastic resin (2), and was cut out in a size of 12 cm ⁇ 12 cm. The thickness of the film was 128 ⁇ m.
- An epoxy resin (1) having a size of 10 cm ⁇ 10 cm (674 g / m 2 ) was produced from the thermoplastic resin (3) and sandwiched between the cut films. At this time, the epoxy resin film was produced from the thermoplastic resin (2) and arranged so as to be in the center of the cut out film.
- the resin supply material (4) was obtained by heat-sealing in the location 1cm from an end. The resin supply material (4) was in the form of a sheet, and its thickness was 0.82 mm.
- Example 5 5 parts by mass of filler (1) is kneaded with 100 parts by mass of pellets of thermoplastic resin (2) by a twin screw extruder (manufactured by JSW Nippon Steel), and then pellets of about 3 mm are formed using a strand pelletizer. . Using the obtained pellets, a film was produced by a press and cut out in a size of 12 cm ⁇ 12 cm. The thickness of the film was 130 ⁇ m. An epoxy resin (1) having a size of 10 cm ⁇ 10 cm (674 g / m 2 ) was produced from the thermoplastic resin (2) and the filler (1) and sandwiched between the cut films.
- the epoxy resin film was produced from the thermoplastic resin (2) and the filler (1) and arranged so as to be in the center of the cut out film.
- the resin supply material (5) was obtained by heat-sealing in a 1-cm location from an end.
- the resin supply material (5) was in the form of a sheet, and its thickness was 0.82 mm.
- thermoplastic resin (4) was cut out with a size of 12 cm ⁇ 12 cm. The thickness of the film was 127 ⁇ m. Two sheets of the obtained film were laminated, and three sides were heat-sealed at a location 1 cm from the end using a polyimide fusion film to obtain a bag. 6.74 g of epoxy resin (2) was put in the obtained bag, and the remaining one side was heat-sealed at a location 1 cm from the end using a polyimide fused film, to obtain a resin supply material (6).
- the resin supply material (6) was in the form of a sheet, and its thickness was 0.82 mm.
- thermoplastic resin (4) was cut out with a size of 12 cm ⁇ 12 cm.
- An epoxy resin (1) having a size of 10 cm ⁇ 10 cm (674 g / m 2 ) was produced from the thermoplastic resin (4) and sandwiched between the cut out films.
- the epoxy resin film was produced from the thermoplastic resin (4) and arranged so as to be in the center of the cut out film.
- the resin supply material (7) was obtained by heat-sealing in a 0.5-cm location from an end using a polyimide melt
- the resin supply material (7) was sheet-like and its thickness was 0.82 mm. It should be noted that Upilex 125S has high rigidity and is difficult to fit along the laminate of the epoxy resin film, and the heat seal position is outside as compared with the resin supply materials (1) to (6).
- thermoplastic resin (4) was perforated, and holes with a diameter of 1 mm were provided at intervals of 4 mm.
- the film was cut out with a size of 12 cm ⁇ 12 cm.
- Two sheets of the obtained film were laminated, and three sides were heat-sealed at a location 1 cm from the end using a polyimide fusion film to obtain a bag.
- the epoxy resin (2) was put into the obtained bag. However, the epoxy resin (2) leaked from the hole, and it was difficult to obtain a resin supply material.
- ⁇ Method for measuring the thickness (film thickness) of a film made of a thermoplastic resin A film made of a thermoplastic resin used as a coating was cut out in a size of 10 cm ⁇ 10 cm, and the average value of values measured at the center and four corners with a micrometer was taken. In addition, in the case of a tube-shaped film, the film was cut open and it measured in the state without an overlap of a film. The measurement results are shown in Table 3.
- ⁇ Filler aspect ratio> A sample in which the filler was dispersed in water and cast on a slide glass was observed with a laser microscope (VK-9500, manufactured by KEYENCE), and the longest length of any filler was measured to obtain a long axis length. Next, with respect to the same filler, the difference in depth of focus between the upper surface of the slide glass and the upper surface of the filler was measured to obtain a short axis length. A value obtained by dividing the measured major axis length by the minor axis length was obtained. Similarly, values were obtained for a total of 100 samples, and this average was taken as the aspect ratio.
- thermosetting resin in closed space in resin supply material The density (a) of a film made of a thermoplastic resin is measured according to JIS-K-7112 (1999) A method. (2) The apparent density (b) of the thermosetting resin is measured according to JIS-K-6911 (1995). (3) The density (A) of the resin feed material is measured according to JIS-K-7112 (1999) A method. (4) Using the balance, the masses M A , M a , and M b of the resin supply material and the thermoplastic resin and the thermosetting resin constituting the resin supply material are measured.
- thermosetting resin The ratio of the thermosetting resin to the closed space is calculated by the following formulas (I) to (V).
- V A M A / Density (A) (I)
- V a M a / density (a) (II)
- V b M b / apparent density (b) (III)
- V c volume of closed space ⁇ : ratio of thermosetting resin to closed space
- thermosetting resin ⁇ Method for measuring viscosity of thermosetting resin> The viscosity of the thermosetting resin was determined using a dynamic viscoelastic device ARES-2KFRTN1-FCO-STD (manufactured by TA Instruments Inc.) and a flat parallel plate with a diameter of 40 mm on the upper and lower measurement jigs. After setting the thermosetting resin so that the distance between the upper and lower jigs is 1 mm, the measurement start temperature is 30 ° C. and the temperature increase rate is 1.5 ° C. in the torsion mode (measurement frequency: 0.5 Hz). Measured at / min.
- ARES-2KFRTN1-FCO-STD manufactured by TA Instruments Inc.
- thermosetting resin the temperature at which the measured resin viscosity was minimized was defined as T (° C.).
- Table 3 shows the temperature T (° C.) obtained by this measurement and the viscosity of the thermosetting resin at a temperature 20 ° C. lower than the melting point of the thermoplastic resin.
- the viscosity of the thermosetting resin (b) at a temperature 20 ° C. lower than the melting point of the thermoplastic resin is abbreviated as “viscosity of thermosetting resin”.
- ⁇ Tensile test method for coating> Based on JIS K 7127 (1999), a tensile test was performed using a tensile tester (5565 floor-standing universal test system, manufactured by Instron). The tensile test was performed at 25 ° C. and a temperature T (° C.) (for example, 110 ° C. for epoxy resin (1) and 138 ° C. for epoxy resin (2)). In the case of carrying out at temperature T (° C.), a test piece was set in a thermostat having a temperature inside the chamber T (° C.) and left for 5 minutes, and then a tensile test was performed. The value X was obtained by dividing the tensile load F at the yield point by the specimen width W. When the tensile load F was below the detection limit of the testing machine, measurement was impossible, and the value X was determined to be less than 0.01 N / mm.
- Example 6 Using the resin supply material and the base material obtained by the above-described method, the following molding process was performed.
- the epoxy resin (2) was supplied from the resin supply material to the base material, and a fiber-reinforced resin with a good impregnation state was obtained.
- Example 7 Except for using the resin supply material (2), the same molding process as in Example 6 was performed.
- the epoxy resin (2) was supplied from the resin supply material to the base material, and a fiber-reinforced resin having a good impregnation state was obtained.
- Example 8 Using the resin supply material and the base material obtained by the above-described method, the following molding process was performed.
- the epoxy resin (1) was supplied from the resin supply material to the base material, and a fiber-reinforced resin with a good impregnation state was obtained.
- Example 9 Using the resin supply material and the base material obtained by the above-described method, the following molding process was performed.
- Example 10 A molding step similar to that in Example 9 was performed except that the resin supply material (5) was used.
- the epoxy resin (1) was supplied from the resin supply material to the base material, and a fiber-reinforced resin having a good impregnation state was obtained.
- Example 11 Using the resin supply material and the base material obtained by the above-described method, the following molding process was performed.
- Two layers of base materials are arranged on the front and back of the resin supply material (1) (size: 10 cm ⁇ 12 cm). At this time, a base material is arrange
- the preform produced in (1) is placed on a metal plate, covered with a film from above, the space between the metal plate and the film is sealed with a sealing material, and a vacuum pump is used for the space covered with the film. A vacuum state (10 ⁇ 1 Pa) is used.
- the inside temperature is put into a dryer whose temperature is adjusted to 70 ° C. and preheated for 10 minutes. (4) After heating up to 150 ° C. at 3 ° C./min, hold for 40 minutes to cure.
- the epoxy resin (2) was supplied from the resin supply material to the base material, and a fiber-reinforced resin with a good impregnation state was obtained.
- Example 6 preforms could be easily produced.
- Example 11 it was confirmed that the material was suitable for a molding method capable of molding a low pressure and complex shape such as vacuum pressure molding. Further, by using these materials, it was possible to easily produce a fiber reinforced resin without using an extra auxiliary material.
- the epoxy resin (2) was not supplied from the resin supply material to the base material, and a fiber reinforced resin could not be obtained. That is, a cured product of epoxy resin (2) wrapped in Iupilex and a dry substrate were obtained.
- Example 5 A molding step similar to that in Example 9 was performed except that the resin supply material (7) was used. As a result, the epoxy resin (1) was not supplied from the resin supply material to the base material, and a fiber reinforced resin could not be obtained. That is, a cured product of epoxy resin (1) wrapped in Iupilex and a dry substrate were obtained.
- the resin supply material of the present invention and the fiber reinforced resin production method using the resin supply material are suitably used for sports applications, general industrial applications, and aerospace applications. More specifically, in general industrial applications, structural materials such as automobiles, ships and windmills, semi-structural materials, roofing materials, electronic trays such as IC trays and laptop computer housings, and repair reinforcement materials. Preferably used. In aerospace applications, it is suitably used for structural materials such as aircraft, rockets, and artificial satellites, and semi-structured materials.
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Abstract
Description
Wfi=Wf1/(Wf1+Wr1)×100(%)・・・(I)
Wf1:樹脂供給材料内繊維重量(g)
Wr1:樹脂供給材料内樹脂重量(g)
Vfi=Vf1/Vp1×100(%)・・・(II)
Vf1:樹脂供給材料内繊維体積(mm3)
Vp1:樹脂供給材料の体積(mm3)
温度T:熱硬化性樹脂を30℃から1.5℃/分の昇温速度で加熱したときに、熱硬化性樹脂の粘度が極小となる温度
R=t0/t1・・・(V)
t0:ウェブの初期厚み(mm)
t1:ウェブに0.1MPaで加圧した状態の厚み(mm)
図1に示すように、本発明は、強化繊維と樹脂からなる樹脂供給材料である。図1に示すように、かかる樹脂供給材料1は、該樹脂供給材料1を基材2と積層してプリフォーム3を作製し、該プリフォーム3を、例えば閉空間内で加熱加圧し、樹脂供給材料1から基材2に樹脂を供給することにより、繊維強化樹脂の成形を可能とする。
Wf1:樹脂供給材料内繊維重量(g)
Wr1:樹脂供給材料内樹脂重量(g)
Vf1:樹脂供給材料内繊維体積(mm3)
Vp1:樹脂供給材料の体積(mm3)
Vfi=Faw/ρ/T1/10(%)
Faw:強化繊維の目付(g/m2)
ρ:強化繊維の密度(g/cm3)
T1:樹脂供給材料の厚さ(mm)
Wr1:成形前の樹脂供給材料内樹脂重量(g)
Wr2:成形後の樹脂供給材料内樹脂重量(g)
Vfi:成形前の繊維体積含有率(%)
Vft:成形後の繊維体積含有率(%)
Vft=Faw/ρ/T1/10(%)
Faw:強化繊維の目付(g/m2)
ρ:強化繊維の密度(g/cm3)
T1:樹脂供給材料の厚さ(mm)
X-Y面の繊維二次元配向角の平均値は、以下の手順I、IIで測定する。なお、上述のとおり、X軸、Y軸、Z軸は互いに直交しており、X-Y面は基材面内、Z軸は基材厚さ方向である。
II.上記Iの測定を別の強化繊維単繊維に着目して合計5回繰り返し、その平均値を繊維二次元配向角の平均値として算出する。
X-Y面と直交する面の繊維二次元配向角の平均値は、以下の手順I、IIで測定する。
II.上記Iの測定を合計50本の強化繊維単繊維で実施し、その平均値をX-Y面と直交する面の繊維二次元配向角の平均値として算出する。
炭素繊維を秤量(W1)した後、50リットル/分の窒素気流中、温度450℃に設定した電気炉に15分間放置し、バインダーを完全に熱分解させる。そして、20リットル/分の乾燥窒素気流中の容器に移し、15分間冷却した後の炭素繊維を秤量(W2)して、次式によりバインダー付着量を求める。
参考例1(強化繊維(炭素繊維))
PANを主成分とする共重合体から紡糸、焼成処理、表面酸化処理を行い、総単繊維数12,000本の連続炭素繊維を得た。この連続炭素繊維の特性は次に示す通りであった。
単位長さ当たりの質量:0.8g/m
比重:1.8
引張強度:4600MPa
引張弾性率:220GPa
“jER(登録商標)”1007(三菱化学(株)製)を40質量部、“jER(登録商標)”630(三菱化学(株)製)を20質量部、“エピクロン(登録商標)”830(DIC(株)製)を40質量部、硬化剤としてDICY7(三菱化学(株)製)を全エポキシ樹脂成分のエポキシ基に対し、活性水素基が0.9当量となる量、硬化促進剤としてDCMU99(保土谷化学工業(株)製)を2質量部用いて、エポキシ樹脂(1)を調製した。
“jER(登録商標)”630(三菱化学(株)製)を6質量部、“EPON(登録商標)”825(三菱化学(株)製)を19質量部、ジグリシジルアニリン(日本化薬(株)製)を15質量部、“カネエース(登録商標)”MX-416((株)カネカ製)を60質量部、硬化剤として“jERキュア(登録商標)”Wを31質量部、硬化促進剤としてDIC-TBC(DIC(株)製)を1質量部用いて、エポキシ樹脂(2)を調製した。
参考例2で調製したエポキシ樹脂(1)を、リバースロールコーターを使用し離型紙上に塗布し、単位面積当たりの質量が37、74、100g/m2である樹脂フィルムを作製した。
参考例1で得られた炭素繊維をカートリッジカッターで所定の長さにカットし、チョップド炭素繊維を得た。水と界面活性剤(ポリオキシエチレンラウリルエーテル(商品名)、ナカライテクス(株)製)からなる濃度0.1質量%の分散液を作製し、この分散液と上記チョップド炭素繊維とを用いて、抄紙基材の製造装置で抄紙基材を製造した。製造装置は、分散槽としての容器下部に開口コックを有する直径1000mmの円筒形状の容器、分散槽と抄紙槽とを接続する直線状の輸送部(傾斜角30度)を備えている。分散槽の上面の開口部には撹拌機が付属し、開口部からチョップド炭素繊維および分散液(分散媒体)を投入可能である。抄紙槽は、底部に幅500mmの抄紙面を有するメッシュコンベアを備える槽であり、炭素繊維基材(抄紙基材)を運搬可能なコンベアをメッシュコンベアに接続している。抄紙は、分散液中の炭素繊維濃度を調整することで、単位面積当たりの質量を調整した。抄紙した炭素繊維基材にバインダーとしてポリビニルアルコール水溶液(クラレポバール、(株)クラレ製)を5質量%ほど付着させ、140℃の乾燥炉で1時間乾燥し、求める炭素繊維ウェブを得た。平均繊維長は5.8mm、X-Y面の繊維二次元配向角の平均値は47.3°、X-Y面と直交する面の繊維二次元配向角の平均値は80.7°であった。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)(目付1100g/m2)をドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)1層で挟み、参考例3で調製したエポキシ樹脂(2)を40℃、真空と2MPa圧で含浸、その後、3℃/分で昇温し、150℃で40分間ホールドし、コンポジットを成形した。JIS 7164(2005年)に準拠して引張試験を実施したところコンポジット強度は315.3MPaであった。
参考例4で得られたエポキシ樹脂フィルムとドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)15枚を使用して、含浸テストを実施した。手順は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
メラミン樹脂発泡体(BASF(株)製、バソテクトUFグレード、目付670g/m2)をドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)1層で挟み、参考例3で調製したエポキシ樹脂(2)を40℃、真空と2MPa圧で含浸、その後、3℃/分で昇温し、150℃で40分ホールドし、コンポジットを成形した。JIS 7164(2005年)に準拠して引張試験を実施したところコンポジット強度は42.5MPaであった。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加圧、加熱する。
実施例1で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、炭素繊維目付198g/m2)を使用して、平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例3で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して、平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例5で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して、平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例7で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して、平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例9で得られた樹脂供給材料とドライ織物(東レクロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)に参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例11で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)(炭素繊維の目付:100g/m2、大きさ:13.8×13.8cm2)の積層間に、参考例4で得られたエポキシ樹脂フィルム(大きさ:13.8×13.8cm2)を3000g/m2配置し、樹脂供給材料を作製した。表1(a)に示す通り、繊維体積含有率は0.6%、繊維重量含有率は3.2%であった。
実施例13で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)(炭素繊維の目付:100g/m2、大きさ:13.8×13.8cm2)の積層間に、参考例4で得られたエポキシ樹脂フィルム(大きさ:13.8×13.8cm2)を1000g/m2配置し、樹脂供給材料を作製した。表1(a)に示す通り、繊維体積含有率は1.1%、繊維重量含有率は9.1%であった。
実施例15で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)(炭素繊維の目付:500g/m2、大きさ:13.8×13.8cm2)の積層間に、参考例4で得られたエポキシ樹脂フィルム(大きさ:13.8×13.8cm2)を1900g/m2配置し、樹脂供給材料を作製した。表1(a)に示す通り、繊維体積含有率は12.5%、繊維重量含有率は20.8%であった。
実施例17で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)(炭素繊維の目付:1200g/m2、大きさ:13.8×13.8cm2)の積層間に、参考例4で得られたエポキシ樹脂フィルム(大きさ:13.8×13.8cm2)を4300g/m2配置し、樹脂供給材料を作製した。表1(a)に示す通り、繊維体積含有率は14.5%、繊維重量含有率は21.8%であった。
実施例19で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
参考例5で得られた炭素繊維ウェブ(1)を5mm幅に60枚カットし、X-Y面がZ-X面となるように回転させて並べた。目付が220g/m2となるウェブを作製した。X-Y面の二次元配向角の平均値は8.7°、X-Y面と直交する面の繊維二次元配向角の平均値は9.1°(Y-Z面)、45.1°(Z-X面)であった。得られたウェブに参考例2で調製したエポキシ樹脂(1)を含浸させ樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)0.1MPa、70℃で1.5時間ほど加熱する。
実施例21で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
表2に示す通り、JIS K6400-2(硬さ及び圧縮たわみ A-1法、2012年)に準拠して、空隙率90%における、参考例5で得られた樹脂供給材料に用いるための強化繊維として使用されるウェブの圧縮応力(スプリングバック力)を測定したところ、200kPaであった。初期厚みt0は51mm、0.1MPaにおける厚みt1は18mm、t0/t1は2.8であった。
参考例3で調製したエポキシ樹脂(2)は、室温で低粘度のため離型紙なしでは取扱い性が悪く、RFI(レジン フィルム インフュージョン)成形は困難であった。
参考例1で得られた炭素繊維束をカートリッジカッターで25mm長にカットし、樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)200g/m2の樹脂フィルムで挟む。
(3)70℃で1時間ほど熱処理する。
比較例2で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
ドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用し、樹脂供給材料を作製した。含浸工程は下記の通りである。
(2)70℃で1時間ほど熱処理する。
比較例4で得られた樹脂供給材料とドライ織物(東レ(株)製クロス、品番:CO6343B、平織、目付198g/m2)を使用して平板を作製した。成形工程は下記の通りである。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
表2に示す通り、JIS K6400-2(硬さ及び圧縮たわみ A-1法、2012年)に準拠して、空隙率90%における、樹脂供給材料に用いるための強化繊維とは異なるメラミン樹脂発泡体(BASF製、バソテクトUFグレード)の圧縮応力(スプリングバック力)を測定したところ、210kPaであった。初期厚みt0は50mm、0.1MPaにおける厚みt1は4mm、t0/t1は12.5であった。
表2に示す通り、JIS K6400-2(硬さ及び圧縮たわみ A-1法、2012年)に準拠して、空隙率90%における、樹脂供給材料に用いるための強化繊維とは異なるポリエーテル系ポリウレタンフォーム((株)イノアックコーポレーション、品名:ECT)の圧縮応力(スプリングバック力)を測定したところ、20kPaであった。初期厚みt0は50mm、0.1MPaにおける厚みt1は2.5mm、t0/t1は20であった。
本発明は、熱可塑性樹脂からなる被膜と熱硬化性樹脂から構成される樹脂供給材料である。図1に示すように、かかる樹脂供給材料1は、該樹脂供給材料1を基材2と積層してプリフォーム3を作製し、該プリフォーム3を、例えば閉空間内で加熱加圧し、樹脂供給材料1から基材2に熱硬化性樹脂を供給することにより、繊維強化樹脂を製造することを可能とする。すなわち、熱硬化性樹脂が、繊維強化樹脂のマトリックス樹脂となる。
以下、実施例によって、本発明について、より具体的に説明する。また、本発明はこれらの実施例によって限定されるものではない。
[熱可塑性樹脂]
熱可塑性樹脂(1):1700J((株)プライムポリマー製、高密度ポリエチレンペレット、融点135℃)
熱可塑性樹脂(2):CM4000(東レ(株)製、3元共重合ポリアミド樹脂(ポリアミド6/66/610)ペレット、融点150℃)
熱可塑性樹脂(3):J106MG((株)プライムポリマー製、ポリプロピレンペレット、融点165℃)
熱可塑性樹脂(4):ユーピレックス125S((株)宇部興産製、ポリイミドフィルム、融点なし)
エポキシ樹脂(1):
“アラルダイド(登録商標)”MY0600(ハンツマン・ジャパン(株)製)を50質量部、“EPICLON(登録商標)”830(DIC製)を50質量部、ビス(4-アミノフェニル)スルホン(東京化成工業(株)製)を40質量部、3-ヒドロキシ-2-ナフトエ酸ヒドラジド(大塚化学(株)製)を5質量部、スミカエクセル5003P(住友化学製)を30質量部用いて、エポキシ樹脂(1)を調製した。エポキシ樹脂(1)の粘度が極小となる温度Tは138℃、40℃における粘度は2380Pa・sであった。得られたエポキシ樹脂(1)を、リバースロールコーターを使用し離型紙上に塗布し、単位面積当たりの質量がそれぞれ100g/m2、37g/m2であるエポキシ樹脂フィルムを作製した。このとき、目的に応じてこれらのフィルムを積層することで、フィルムの単位面積当たりの質量を変更した。
“jER(登録商標)”630(三菱化学(株)製)を6質量部、“EPON(登録商標)”825(三菱化学(株)製)を19質量部、ジグリシジルアニリン(日本化薬製)を15質量部、“カネエース(登録商標)”MX-416(カネカ製)を60質量部、硬化剤として“jERキュア(登録商標)”Wを31質量部、硬化促進剤としてDIC-TBC(DIC製)を1質量部用いて、エポキシ樹脂(2)を調製した。エポキシ樹脂(2)の粘度が極小となる温度Tは110℃、40℃における粘度は5.6Pa・sであった。
炭素繊維織物(1):CO6343B(東レ(株)製、平織、目付198g/m2)
フィラー(1)
工業用雲母粉A-21S(商品名)((株)ヤマグチマイカ製、平均粒径23μm、アスペクト比70)
(実施例1)
熱可塑性樹脂(1)のペレットを用い、インフレーション製膜法にて、幅10cmのチューブ状のフィルムを製造し、12cmの長さに裁断した。フィルムの厚みは87μmであった。チューブ状のフィルムの口の一方を端から1cmの箇所でヒートシールし、袋とした。得られた袋にエポキシ樹脂(2)を6.74g入れ、もう一方の口を端から1cmの箇所でヒートシールすることで、樹脂供給材料(1)を得た。樹脂供給材料(1)はシート状であり、その厚みは0.74mmであった。
熱可塑性樹脂(3)のペレットを用い、インフレーション製膜法にて、幅10cmのチューブ状のフィルムを製造し、12cmの長さに裁断した。フィルムの厚みは93μmであった。チューブ状のフィルムの口の一方を端から1cmの箇所でヒートシールし、袋とした。得られた袋にエポキシ樹脂(2)を6.74g入れ、もう一方の口を端から1cmの箇所でヒートシールすることで、樹脂供給材料(2)を得た。樹脂供給材料(2)はシート状であり、その厚みは0.75mmであった。
熱可塑性樹脂(1)のペレットを用い、インフレーション製膜法にて、幅10cmのチューブ状のフィルムを製造し、12cmの長さに裁断した。フィルムの厚みは87μmであった。チューブ状のフィルムの口の一方を端から1cmの箇所でヒートシールし、袋とした。得られた袋に10cm×10cmのサイズのエポキシ樹脂(1)(674g/m2)を入れ、もう一方の口を端から1cmの箇所でヒートシールすることで、樹脂供給材料(3)を得た。樹脂供給材料(3)はシート状であり、その厚みは0.74mmであった。
熱可塑性樹脂(2)のペレットを用い、プレス機によりフィルムを製造し、12cm×12cmのサイズで切り出した。フィルムの厚みは128μmであった。10cm×10cmのサイズのエポキシ樹脂(1)(674g/m2)を熱可塑性樹脂(3)より製造し、切り出したフィルムで挟んだ。このとき、エポキシ樹脂フィルムが熱可塑性樹脂(2)より製造し、切り出したフィルムの中央にくるように配置した。得られた積層体の4辺について、端から1cmの箇所でヒートシールすることで、樹脂供給材料(4)を得た。樹脂供給材料(4)はシート状であり、その厚みは0.82mmであった。
二軸押出機(JSW日本製鋼所製)により熱可塑性樹脂(2)のペレット100質量部に対し、フィラー(1)を5質量部混練した後、ストランド用ペレタイザーを用い、3mm程度のペレットとした。得られたペレットを用い、プレス機によりフィルムを製造し、12cm×12cmのサイズで切り出した。フィルムの厚みは130μmであった。10cm×10cmのサイズのエポキシ樹脂(1)(674g/m2)を、熱可塑性樹脂(2)とフィラー(1)より製造し、切り出したフィルムで挟んだ。このとき、エポキシ樹脂フィルムが、熱可塑性樹脂(2)とフィラー(1)より製造し、切り出したフィルムの中央にくるように配置した。得られた積層体の4辺について、端から1cmの箇所でヒートシールすることで、樹脂供給材料(5)を得た。樹脂供給材料(5)はシート状であり、その厚みは0.82mmであった。
熱可塑性樹脂(4)を12cm×12cmのサイズで切り出した。フィルムの厚みは127μmであった。得られたフィルムを2枚積層し、ポリイミド融着フィルムを用いて端から1cmの箇所で3辺をヒートシールし、袋とした。得られた袋にエポキシ樹脂(2)を6.74gいれ、残りの1辺をポリイミド融着フィルムを用いて端から1cmの箇所でヒートシールすることで、樹脂供給材料(6)を得た。樹脂供給材料(6)はシート状であり、その厚みは0.82mmであった。
熱可塑性樹脂(4)を12cm×12cmのサイズで切り出した。10cm×10cmのサイズのエポキシ樹脂(1)(674g/m2)を熱可塑性樹脂(4)より製造し、切り出したフィルムで挟んだ。このとき、エポキシ樹脂フィルムが熱可塑性樹脂(4)より製造し、切り出したフィルムの中央にくるように配置した。得られた積層体の4辺について、ポリイミド融着フィルムを用いて端から0.5cmの箇所でヒートシールすることで、樹脂供給材料(7)を得た。樹脂供給材料(7)はシート状であり、その厚みは0.82mmであった。なお、ユーピレックス125Sは剛性が高く、エポキシ樹脂フィルムの積層体に沿わせることが困難であり、樹脂供給材料(1)~(6)と比較してヒートシールの位置が外側となった。
熱可塑性樹脂(4)に有孔加工を施し、直径1mmの孔を4mm間隔で設けた。該フィルムを12cm×12cmのサイズで切り出した。得られたフィルムを2枚積層し、ポリイミド融着フィルムを用いて端から1cmの箇所で3辺をヒートシールし、袋とした。得られた袋にエポキシ樹脂(2)をいれた。しかし、エポキシ樹脂(2)が前記孔から漏れ出してしまい、樹脂供給材料を得ることは困難であった。
被膜として使用する熱可塑性樹脂からなるフィルムを10cm×10cmのサイズで切り出し、マイクロメーターで中央部と四隅で5点計測した値の平均値とした。なお、チューブ状のフィルムの場合は、フィルムを切り開き、フィルムの重なりがない状態で計測した。測定結果を表3に記載する。
圧縮試験機(5582床置き型万能試験システム、インストロン製)のステージに載置した樹脂供給材料を、樹脂供給材料に荷重が0.01Nかかる状態となるように、圧子で押し付けた。その状態でのステージの上面と圧子の下面との距離を樹脂供給材料の厚みとした。測定結果を表3に記載する。
フィラーを水中に分散させ、スライドガラス上にキャストしたサンプルをレーザー顕微鏡(KEYENCE社製VK-9500)により観察し、任意のフィラーについて最長となる長さを計測し、長軸長さとした。次に、同じフィラーについて、スライドガラスの上面とフィラーの上面との焦点深度差を計測し、短軸長さとした。計測した長軸長さを短軸長さで除した値を求めた。同様に全部で100個のサンプルについて値を求め、この平均をアスペクト比とした。
(1)熱可塑性樹脂からなるフィルムの密度(a)をJIS-K-7112(1999)A法に準拠して測定する。
(2)熱硬化性樹脂の見かけ密度(b)をJIS-K-6911(1995)に準拠して測定する。
(3)樹脂供給材料の密度(A)をJIS-K-7112(1999)A法に準拠して測定する。
(4)天びんを用いて、樹脂供給材料および樹脂供給材料を構成する熱可塑性樹脂ならびに熱硬化性樹脂の質量MA、Ma、Mbを測定する。
VA=MA/密度(A)・・・(I)
Va=Ma/密度(a)・・・(II)
Vb=Mb/見かけ密度(b)・・・(III)
Vc=VA-Va・・・(IV)
α(%)=Vb/Vc×100・・・(V)
Vc:閉空間の容積
α:熱硬化性樹脂が閉空間に占める割合
熱硬化性樹脂の粘度は、動的粘弾性装置ARES-2KFRTN1-FCO-STD(ティー・エイ・インスツルメント(株)製)を用い、上下部測定治具に直径40mmの平板のパラレルプレートを用い、上部と下部の治具間が1mmとなるように、熱硬化性樹脂をセット後、ねじりモード(測定周波数:0.5Hz)で、測定開始温度を30℃、昇温速度1.5℃/分で測定した。
JIS-K-7121(1987)に準拠し、示差走査熱量計Q2000(ティー・エイ・インスツルメント(株)製)を用いて測定した。測定結果を表3に記載する。
JIS K 7127(1999)に準拠して引張試験機(5565床置き型万能試験システム、インストロン製)を用いて引張試験を実施した。引張試験は25℃、および温度T(℃)(たとえば、エポキシ樹脂(1)では110℃、エポキシ樹脂(2)では138℃)で実施した。温度T(℃)で実施する場合は、庫内温度を温度T(℃)とした恒温槽内に試験片をセットしてから5分間放置した後、引張試験を行った。降伏点における引張荷重Fを試験片幅Wで除して値Xを得た。引張荷重Fが試験機の検出限界以下の場合は測定不可とし、値Xを0.01N/mm未満と判定した。
成型工程後に、含浸状態の良好な繊維強化樹脂が得られた場合を○、樹脂供給材料から基材へ熱硬化性樹脂が供給されず、繊維強化樹脂を得ることができなかった場合を×とした。判定結果を表4に記載する。
上述の方法で得られた樹脂供給材料と基材を使用して、以下の成形工程を実施した。
(2)(1)の積層体をプレス機でゼロ圧、70℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で150℃まで昇温後、40分間ホールドし硬化する。
樹脂供給材料(2)を用いる以外は、実施例6と同様の成形工程を実施した。樹脂供給材料から基材へエポキシ樹脂(2)が供給され、含浸状態の良好な繊維強化樹脂が得られた。
上述の方法で得られた樹脂供給材料と基材を使用して、以下の成形工程を実施した。
(2)(1)の積層体をプレス機でゼロ圧、130℃で10分ほど予熱する。
(3)1MPaで加圧する。
(4)3℃/分で180℃まで昇温後、40分間ホールドし硬化する。
上述の方法で得られた樹脂供給材料と基材を使用して、以下の成形工程を実施した。
(2)~(4)は実施例8と同様の成形工程を実施した。樹脂供給材料から基材へエポキシ樹脂(1)が供給され、含浸状態の良好な繊維強化樹脂が得られた。
樹脂供給材料(5)を用いる以外は、実施例9と同様の成形工程を実施した。樹脂供給材料から基材へエポキシ樹脂(1)が供給され、含浸状態の良好な繊維強化樹脂が得られた。
上述の方法で得られた樹脂供給材料と基材を使用して、以下の成形工程を実施した。
(2)(1)で作製したプリフォームを金属板の上に配し、上からフィルムで覆い、金属板とフィルムとの間をシール材でシールし、フィルムで覆われた空間について真空ポンプを用いて真空状態(10-1Pa)とする。
(3)この状態を維持したまま庫内の温度が70℃に温調された乾燥機内に入れ、10分間予熱する。
(4)3℃/minで150℃まで昇温させた後、40分間ホールドし硬化する。
上述の方法で得られた樹脂供給材料と基材を使用して、以下の成形工程を実施した。
(2)~(4)は実施例6と同様の成形工程を実施した。
樹脂供給材料(7)を用いる以外は、実施例9と同様の成形工程を実施した。その結果、樹脂供給材料から基材へエポキシ樹脂(1)は供給されず、繊維強化樹脂を得ることができなかった。すなわち、ユーピレックスに包まれたエポキシ樹脂(1)の硬化物およびドライな基材が得られた。
2 基材
3 プリフォーム
Claims (24)
- 繊維強化樹脂の成形に用いる樹脂供給材料であって、強化繊維と樹脂からなり、下記式(I)で表される、前記強化繊維の繊維重量含有率Wfiが30%以下である、および/または、下記式(II)で表される、前記強化繊維の繊維体積含有率Vfiが20%以下である樹脂供給材料。
Wfi=Wf1/(Wf1+Wr1)×100(%)・・・(I)
Wf1:樹脂供給材料内繊維重量(g)
Wr1:樹脂供給材料内樹脂重量(g)
Vfi=Vf1/Vp1×100(%)・・・(II)
Vf1:樹脂供給材料内繊維体積(mm3)
Vp1:樹脂供給材料の体積(mm3) - 下記式(III)で表される、前記樹脂の重量の成形前と成形後の変化率Pが0.03~0.99の範囲内になるものである、請求項1に記載の樹脂供給材料。
P=Wr2/Wr1・・・(III)
Wr1:成形前の樹脂供給材料内樹脂重量(g)
Wr2:成形後の樹脂供給材料内樹脂重量(g) - 下記式(IV)で表される、前記強化繊維の体積含有率の成形前と成形後の変化率Qが1.1~30の範囲内になるものである、請求項1または2に記載の樹脂供給材料。
Q=Vft/Vfi・・・(IV)
Vfi:成形前の繊維体積含有率
Vft:成形後の繊維体積含有率 - 繊維強化樹脂の成形に用いる強化繊維と樹脂からなる樹脂供給材料に用いるための強化繊維の使用方法であって、下記式(V)で表される、前記強化繊維の成形前と成形後の厚み変化率Rが1.1~10の範囲内になるウェブとして使用する、強化繊維の使用方法。
R=t0/t1・・・(V)
t0:ウェブの初期厚み(mm)
t1:ウェブに0.1MPaで加圧した状態の厚み(mm) - 前記強化繊維が、下記式(V)で表される、前記強化繊維の成形前と成形後の厚み変化率Rが1.1~10の範囲内になるウェブである、請求項1~3のいずれかに記載の樹脂供給材料。
R=t0/t1・・・(V)
t0:ウェブの初期厚み(mm)
t1:ウェブに0.1MPaで加圧した状態の厚み(mm) - 前記強化繊維が、空隙率90%における圧縮応力(スプリングバック力)が5kPa以上のウェブである、請求項1~3、5のいずれかに記載の樹脂供給材料。
- 前記強化繊維が、基材形態である、請求項1~3、5、6のいずれかに記載の樹脂供給材料。
- 前記強化繊維のX-Y面と直交する面の繊維二次元配向角の平均値が5~85度である、請求項1~3、5~7のいずれかに記載の樹脂供給材料。
- 前記強化繊維のX-Y面の繊維二次元配向角の平均値が5度以上である、請求項1~3、5~8のいずれかに記載の樹脂供給材料。
- 前記強化繊維が、ガラス繊維、炭素繊維、アラミド繊維、および金属繊維から選択される少なくとも1種である、請求項1~3、5~9のいずれかに記載の樹脂供給材料。
- 前記強化繊維の平均繊維長が0.1~100mmである、請求項1~3、5~10のいずれかに記載の樹脂供給材料。
- 繊維強化樹脂の成形に用いる樹脂供給材料であって、熱可塑性樹脂からなる被膜と、熱硬化性樹脂から構成されており、前記被膜の引張試験(JIS K 7127(1999))で測定される降伏点における引張荷重Fを試験片の幅Wで除した値Xが、25℃において1N/mm以上であり、かつ以下に示す温度Tにおいて1N/mm未満である、樹脂供給材料。
温度T:熱硬化性樹脂を30℃から1.5℃/分の昇温速度で加熱したときに、熱硬化性樹脂の粘度が極小となる温度 - 前記被膜が閉空間を形成してなる、請求項12に記載の樹脂供給材料。
- 前記熱硬化性樹脂が前記閉空間の90%以上を占める、請求項13に記載の樹脂供給材料。
- 前記被膜がシート状である、請求項12~14のいずれかに記載の樹脂供給材料。
- 前記被膜の厚みが1μm以上300μm以下である、請求項12~15のいずれかに記載の樹脂供給材料。
- 前記熱可塑性樹脂の融点が100℃以上200℃以下である、請求項12~16のいずれかに記載の樹脂供給材料。
- 前記熱可塑性樹脂の融点より20℃低い温度における前記熱硬化性樹脂の粘度が100Pa・s以下である、請求項12~17のいずれかに記載の樹脂供給材料。
- 前記熱可塑性樹脂の主成分がポリオレフィン、ポリアミド、ポリエステルから選択される少なくとも1種である、請求項12~18のいずれかに記載の樹脂供給材料。
- 前記熱可塑性樹脂が、フィラー、可塑剤から選択される少なくとも1種の添加剤を含む、請求項12~19のいずれかに記載の樹脂供給材料。
- 前記熱硬化性樹脂の40℃における粘度が0.01Pa・s以上4000Pa・s以下である、請求項12~20のいずれかに記載の樹脂供給材料。
- 請求項1~3、5~21のいずれかに記載の樹脂供給材料と基材とを積層し、一体化させてなるプリフォーム。
- 前記基材が、強化繊維からなる織物基材、一方向基材、およびマット基材から選択される少なくとも1種の基材である、請求項22に記載のプリフォーム。
- 請求項22または23に記載のプリフォームを加熱、加圧することにより、前記樹脂供給材料から前記基材に前記樹脂または前記熱硬化性樹脂を供給し、成形する繊維強化樹脂の製造方法。
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CN110234481A (zh) * | 2017-02-02 | 2019-09-13 | 东丽株式会社 | 纤维增强树脂成型材料 |
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