WO2017038697A1 - 強化繊維基材及びその製造方法、並びに賦形布帛及びその製造方法、並びに繊維強化プラスチック構造体 - Google Patents
強化繊維基材及びその製造方法、並びに賦形布帛及びその製造方法、並びに繊維強化プラスチック構造体 Download PDFInfo
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- WO2017038697A1 WO2017038697A1 PCT/JP2016/075023 JP2016075023W WO2017038697A1 WO 2017038697 A1 WO2017038697 A1 WO 2017038697A1 JP 2016075023 W JP2016075023 W JP 2016075023W WO 2017038697 A1 WO2017038697 A1 WO 2017038697A1
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- binder
- reinforcing fiber
- heat
- fusible
- fiber base
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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
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
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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
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/105—Coating or impregnating independently of the moulding or shaping step of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C70/46—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
- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
Definitions
- the present invention relates to a reinforcing fiber base on which a heat-fusible binder is disposed under predetermined conditions, a method for producing the same, a method for producing a shaped fabric using the reinforcing fiber base, and the shaped fabric.
- the present invention relates to a fiber reinforced plastic structure obtained using
- This shaped fabric is generally called a preform, and Resin Transfer Molding (hereinafter referred to as RTM) in which a preform is impregnated with a matrix resin to form a structure of fiber reinforced plastic (hereinafter referred to as FRP).
- RTM Resin Transfer Molding
- FRP fiber reinforced plastic
- FRP fiber reinforced plastic
- prepreg / autoclave As a method for manufacturing an FRP molded product, a so-called prepreg / autoclave in which a preform having a shape of a molded product to be molded in advance is formed by a prepreg and then cured in an autoclave in which predetermined temperature and pressure conditions are set. Molding methods were common. However, in recent years, the RTM method has attracted attention and is gradually spreading in order to reduce manufacturing costs.
- Patent Document 1 does not specifically disclose a method of applying a binder.
- the step of spraying as a binder is simple. Therefore, it is preferable to form a solid powder that can be dispersed on the surface of the reinforcing fiber in the form of dots, lines, or discontinuous lines at room temperature.
- the binder is transferred from the nozzle or spraying spout to the spreading surface of the reinforcing fiber base.
- this scattering may be noticeable.
- the present invention has been made to solve these problems, and a specific object thereof is to impart excellent shape retention and matrix resin impregnation to the shaped fabric and have excellent productivity.
- the object is to provide a reinforcing fiber base and a method for producing the same, and to provide a shaped fabric using the reinforcing fiber base and a fiber reinforced plastic structure.
- the gist of the present invention is as follows. (1) A thermal fiber base having a plurality of heat-fusible binders arranged on the surface, and having a projected area equivalent circle diameter less than 300 times the average diameter of the reinforcing fibers constituting the reinforcing fiber base A reinforcing fiber substrate in which the total area of the adhesive binder is 10% or less with respect to the total area of the heat-fusible binder disposed on the surface. (2) The total area of the heat-fusible binder having a projected area equivalent circle diameter less than 300 times the average diameter is 1% or more with respect to the total area of the heat-fusible binder (1 ) Reinforcing fiber substrate as described.
- a binder permeable sheet having a required thickness and having a transmission pattern by binder transmission holes on the reinforcing fiber substrate Arranging a powdery binder on the surface of the binder permeable sheet; Storing the powdered binder in the binder permeation hole; A step of relatively separating the binder permeable sheet from the binder application surface of the reinforcing fiber base; A method for producing a reinforced fiber base material, wherein a heat-fusible binder is disposed on the surface, the step of transferring the powdery binder stored in the permeation holes to the binder application surface of the reinforced fiber base material at the time of separation.
- the reinforcing fiber constituting the reinforcing fiber substrate of the present invention examples include carbon fiber, glass fiber, Tyranno fiber, aramid fiber, silicon nitride fiber, high-strength polyester fiber, boron fiber, alumina fiber, nylon fiber, and mineral fiber. Etc. Among these, carbon fibers are preferable because they are excellent in specific strength and specific elasticity. When carbon fibers are used as the reinforcing fibers, those having an average diameter (single fiber) of, for example, about 3 to 20 ⁇ m can be used.
- the reinforcing fiber substrate of the present invention is composed of a fabric such as a woven fabric, a knitted fabric, a non-crimp fabric, and a non-woven fabric containing the above-described reinforcing fibers.
- a heat-fusible binder having a predetermined shape set according to the shape of the intended shaped fabric is disposed on the surface of the reinforcing fiber substrate of the present invention.
- This heat-fusible binder is a resin that is solid at room temperature, and can be selected from thermosetting resins and thermoplastic resins.
- the thermosetting resin include unsaturated polyester resin, epoxy resin, vinyl ester resin, phenol resin, epoxy acrylate resin, urethane acrylate resin, phenoxy resin, alkyd resin, urethane resin, maleimide resin, cyanate resin, and the like.
- thermoplastic resin examples include polyolefin resins, acrylic resins, polyamide resins, polyester resins, polyphenylene sulfide resins, polyether ketone resins, polyether sulfone resins, and aromatic polyamide resins. In consideration of compatibility with the matrix resin used in the RTM, one or more of the above resins can be appropriately selected and used.
- the heat-fusible binder is used to heat the laminated reinforcing fiber bases at the time of manufacturing the above-mentioned shaped fabric, thereby heat-sealing them, and until this shaped fabric is subjected to RTM, this shaped fabric. It has the function to hold the shape of.
- the heat-fusible binder may be, for example, a state in which an aggregate of powders is arranged in a predetermined shape on the base material.
- the shape stability of the heat-fusible binder and the reinforcing fiber base material From the viewpoint of excellent workability at the time of laminating, it is preferable to be bonded onto the reinforcing fiber base in an integrated state.
- the powder heat-fusible binder is disposed on the substrate as described above, in this state, the powder heat-fusible binder is heated to be fused and integrated. It can be fixed on the material.
- the thickness of the heat-fusible binder constituting the present invention is preferably not more than 300 times the average diameter of the reinforcing fibers because the unevenness on the surface of the intended shaped fabric can be reduced.
- the thickness of the heat-fusible binder constituting the present invention is 600 ⁇ m or less. Is preferable, and it is more preferable to set it as 300 micrometers or less.
- a heat having a projected area equivalent circle diameter of less than 300 times the average diameter of the reinforcing fibers constituting the reinforcing fiber base In the reinforcing fiber base of the present invention in which a heat-fusible binder is arranged on the surface of the present invention, a heat having a projected area equivalent circle diameter of less than 300 times the average diameter of the reinforcing fibers constituting the reinforcing fiber base.
- the total area of the fusible binder needs to be 10% or less with respect to the total area of the heat fusible binder arranged on the surface.
- the total of the above areas is 1% or more of the total area of the heat-fusible binder, so that the productivity of the reinforcing fiber substrate is not impaired.
- the shape-retaining property of the shaped fabric and the matrix resin impregnation property of the fiber-reinforced plastic structure can be maintained. More preferably, it is 2% or more, More preferably, it is 3% or more.
- the projected area equivalent circle diameter is an equivalent circle diameter known as the Haywood diameter, and in the present invention, in the individual heat-fusible binder disposed on the surface of the reinforcing fiber base, It means the diameter of a circle having an area equal to the projected area on the surface of the reinforcing fiber substrate.
- the ratio of the total area of the heat-fusible binder to the area of the reinforcing fiber substrate is preferably in the range of 5 to 70%.
- the binder peel strength between the reinforcing fiber bases constituting the above-mentioned shaped fabric becomes a sufficient level, and the shape retaining property of the shaped fabric tends to be good. Because there is. Preferably it is 10% or more, More preferably, it is 20% or more. In addition, by setting the ratio to 70% or less, the target fiber reinforcement caused by the matrix resin flow path between the reinforcing fiber bases being blocked during the RTM using the above-described shaped fabric. This is because defects in the matrix resin impregnation of the plastic structure tend not to occur. Preferably, it is 60% or less, more preferably 50% or less.
- a heat-fusible binder having a sieve diameter of 3000 times or less the average diameter of the reinforcing fibers is disposed. This is because the resin flow path between the reinforcing fiber bases is blocked during the RTM using the above-mentioned shaped fabric by setting the sieve diameter to 3000 times or less of the average diameter of the reinforcing fibers. This is because the target fiber-reinforced plastic structure is less likely to be poorly impregnated with the matrix resin due to the above. Preferably, it is 2500 times or less, more preferably 2000 times or less.
- the sieve diameter of the heat-fusible binder disposed on the base material as a binder is 300 times or more of the average diameter of the reinforcing fibers. This is preferable because the shape retainability of the fabric tends to be excellent. More preferably, it is 500 times or more, More preferably, it is 800 times or more.
- the sieve diameter in the present invention is the case where a solid substance having the same shape as the individual heat-fusible binder disposed on the surface of the reinforcing fiber substrate is passed through a sieve having a true circular opening. This means the minimum value of the mesh that can be passed through.
- the shape of the heat-fusible binder disposed for the purpose of this binder is not particularly limited, and may be, for example, a dot shape, a discontinuous line shape, or a continuous line shape.
- the shape of the heat-fusible binder and the arrangement position thereof can be appropriately selected in consideration of the shape of the above-mentioned shaped fabric, and further the reinforcing fiber base.
- the aggregate pattern of substantially the same heat-fusible binder can be arranged in each layer, so that the quality is stabilized. Therefore, by using this shaped fabric, a fiber reinforced plastic structure with little variation in physical properties can be produced.
- the above-mentioned reinforcing fiber substrate of the present invention can be produced, for example, by performing the following steps.
- the arrangement density of the binder permeation holes in the pattern formed on the binder permeable sheet can be changed as appropriate, and the shape and dimensions of the powder binder can be accurately reproduced as designed.
- the binder coating density can be adjusted in consideration of the shape of the shaped fabric and the matrix resin impregnation property during RTM.
- the powdery binder used in the above step can be a solid binder at room temperature and can express heat-fusibility by heating, and can be appropriately selected from the above-mentioned thermosetting resins and thermoplastic resins. it can.
- the average particle size of the powder binder is preferably in the range of 10 to 300 ⁇ m. This is because the scattering of the binder during the coating of the binder tends to be suppressed by setting the average particle diameter to 10 ⁇ m or more. More preferably, it is 30 micrometers or more, More preferably, it is 50 micrometers or more. Moreover, it is because it exists in the tendency for the adhesiveness of a binder and a reinforced fiber base material to become favorable because this average particle diameter shall be 300 micrometers or less. More preferably, it is 250 micrometers or less, More preferably, it is 200 micrometers or less.
- a transmission pattern by a binder permeable hole formed of a dot and / or a line shape can be appropriately selected.
- the binder transmission sheet having such a predetermined transmission pattern can be continuously used to repeatedly arrange substantially the same aggregate pattern of the binder on the substrate. And shortening the time can be achieved.
- the material of the binder permeable sheet is not particularly limited.
- it is a mesh fabric woven using a synthetic resin monofilament, spun yarn, stainless steel wire, a porous synthetic resin plate, or a metal plate.
- a mesh woven fabric is preferable from the viewpoint of excellent followability to a reinforcing fiber substrate having irregularities on the surface.
- the mesh size when the mesh fabric is used is not particularly limited, but is preferably in the range of 100 to 1000 ⁇ m from the viewpoint of permeability of the powdery binder to the mesh.
- the thickness of the binder permeable sheet is not particularly limited, but is preferably in the range of 30 to 300 ⁇ m from the standpoint of followability to the reinforcing fiber base and durability.
- the application amount of the one-dot or one-line binder is controlled by adjusting the pressing force to the binder permeation sheet using, for example, a spatula.
- film formation of the powdery binder in the non-porous region can be suppressed, and the flow of the matrix resin in the thickness direction of the substrate during RTM tends to be smooth.
- the adhesive strength of the binder with respect to the reinforcing fiber substrate is accurately controlled by changing the aperture ratio of the binder permeable sheet at a specific location, for example, by adjusting the coating amount of the 1-dot or 1-line binder.
- the adhesive strength can be locally increased, even a shaped fabric having a complicated shape can be provided with a sufficient shape retention force.
- the above-mentioned shaped fabric is prepared by preparing a plurality of the reinforcing fiber bases of the present invention produced by the above process, laminating them so that the binder arrangement surface faces the same surface, and further, the plurality of laminated sheets It can be manufactured by sandwiching a reinforcing fiber substrate between two or more shaping dies and heating and pressing to fuse each reinforcing fiber substrate and simultaneously fuse the binder existing between the reinforcing fiber substrates. it can.
- the heating and pressing conditions can be appropriately selected according to the shape of the shaped fabric, the type of binder, and the like.
- a fiber-reinforced plastic structure can be produced by impregnating and curing a matrix resin in a shaped fabric produced according to the present invention using RTM.
- the RTM conditions and the type of matrix resin can be appropriately selected according to the shape and application of the fiber reinforced plastic structure.
- FRP reinforcing fiber base material is a woven fabric, knitted fabric, non-crimp fabric, non-crimp fabric, etc. made of the above-mentioned reinforcing fibers, on which the heat-fusible binder is arranged.
- a plurality of materials are laminated to form a laminated body, this laminated body is placed on the lower mold of the preform-forming mold, the upper mold is lowered, heated and pressed, and a preform having a predetermined shape (shaped) Fabric).
- a powdered binder made of a thermoplastic resin that locally melts the fibers by heating and pressurizing the mold to keep the preform on the surface of the reinforcing fiber base.
- a coating agent is applied to the entire surface except for the portion where the dot-like binder permeable holes 15 formed along a desired pattern are formed. Part coating agent is removed to form mesh openings (eyes). The powdery binder permeates through the eyes of the mesh part from which the coating agent has been removed.
- the arrangement positions of a large number of binder transmission holes 15 are drilled along a desired pattern.
- the material of the spatula 14 is selected from rubber, wood, and metal, but a rectangular flat plate is generally used.
- the powdery binder 11 is filled in all the binder transmission holes 15 of the binder transmission sheet 12 while being expanded by the spatula 14. At this time, the powdery binder 11 that has not been filled in the binder transmission hole 15 is driven off on the binder transmission sheet 12 to the third frame material 13c opposite to the first frame material 13a as the spatula 14 moves.
- the third frame material 13c gathers in a part of the adjacent area while wiping away the binder 11 remaining on the binder permeable sheet 12.
- FIG. 2 schematically shows the shape of the binder 11 on the reinforcing fiber base 10 and the structure of the binder permeable sheet 12 when the transition is made.
- any of the application shape, the application size, and the application arrangement can be balanced. Since there is no large variation in the binder shape and the dot interval is made uniform, the flow path of the matrix resin is secured even in the subsequent molding of the FRP. In this way, the plurality of reinforcing fiber base materials 10 on which the powdery binders 11 are applied in the form of dots have a laminated body in which the binder application surfaces are stacked in the same direction as shown in FIG.
- the powdered binder is not sprayed or flowed down from the required height to the substrate surface with a nozzle or spray as in the prior art, the surrounding environment is deteriorated by the scattering of the binder. And is not affected by the surrounding environment. That is, the method for producing a reinforcing fiber base according to the present invention is executed with an extremely simple instrument including only the frame 13 and the spatula 14 in which the binder permeable sheet 12 is stretched in a tension state as described above.
- a fixed amount of powder with a predetermined pattern is applied to the reinforcing fiber base 10 by a simple operation of moving the spatula 14 while pressing it against the binder permeable sheet 12.
- the binder 11 can be accurately applied in a dot shape or a line shape with a predetermined interval.
- the reinforcing fiber base after application of the binder it can be fixed by infrared heating or the like immediately after application of the binder before lamination. Since the present invention is a simple instrument, it is easy to automate, and the binder is continuously applied not only in the process of applying the binder to the reinforcing fiber base cut into a predetermined shape but also in the manufacturing process of the reinforcing fiber base. Can be applied and fixed by infrared heating or the like, and a roll-like reinforcing fiber base material can be used as a raw material to similarly apply a binder and fix in a separate process.
- the powdery binder 11 can be applied in particular according to the pattern, the increase / decrease adjustment of the coating amount of the powdery binder 11 at a specific part of the reinforcing fiber base 10 can be easily and reliably performed.
- the coating operation of the powder binder 11 is based on the sliding of the spatula, the film formation of the powder binder 11 in the non-porous region can be suppressed by adjusting the pressing force, and the laminated reinforcing fibers in the RTM molding method.
- the flow of the matrix resin in the thickness direction of the substrate 10 is smoothed.
- Example 1 Carbon fiber non-crimp fabric (TK Industries, TKI300B127T, carbon fiber average diameter: about 7 ⁇ m) is coated with a powder binder (Hexion Epikote 05390), so that it opens in a square arrangement of ⁇ 6.2 mm and a pitch of 10 mm. Used screen. Place the screen on the non-crimp fabric and attach it closely, store the binder at one side edge of the screen, and use a rubber spatula to move the stored binder to the opposite side. Was transferred to a non-crimp fabric, the screen was removed, and the binder was applied.
- TK Industries TKI300B127T, carbon fiber average diameter: about 7 ⁇ m
- a powder binder Hexion Epikote 05390
- the binder is melted by irradiating infrared rays and then cooled to fix the binder.
- the area ratio of the dot-like binder having a sieve diameter of 5.7 to 6.3 mm is 26%, and the projected area has an equivalent circle diameter.
- a reinforcing fiber base material having an area ratio of 1.5 to 1.8 mm fine dot binder of 1.0% (3.7% with respect to the total area of the heat-fusible binder) was obtained.
- a plurality of reinforcing fiber base materials were prepared, laminated such that the binder fixing side faced the same surface, and then sandwiched between the molding dies and heated and pressed to obtain a shaped fabric. This shaped fabric had sufficient interlayer adhesive strength and was excellent in shape stability.
- Example 1 A reinforcing fiber base in which the ratio of the total area of the binder to the area of the non-crimp fabric is 27% under the same conditions as in Example 1 except that the screen binder is not used and the powder binder is dispersed on the non-crimp fabric.
- the material was manufactured.
- this reinforced fiber base material the area ratio of fine dots having a projected area equivalent circle diameter of 0.9 to 1.7 mm to the reinforced fiber base material is 12.6% (relative to the total area of the heat-fusible binder). 46.7%).
- a plurality of reinforcing fiber base materials were prepared and laminated so that the binder fixing side faced the same surface, and then sandwiched between the shaping molds and heated to obtain a shaped fabric.
- the shaped fabric was inferior in shape stability.
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- Engineering & Computer Science (AREA)
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- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Reinforced Plastic Materials (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
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Abstract
Description
(1)表面に熱融着性バインダーが複数配置された強化繊維基材であって、該強化繊維基材を構成する強化繊維の平均直径の300倍未満の投影面積円相当径を有する熱融着性バインダーの面積の合計が、該表面に配置された熱融着性バインダーの総面積に対して10%以下である強化繊維基材。
(2)前記平均直径の300倍未満の投影面積円相当径を有する熱融着性バインダーの面積の合計が、前記熱融着性バインダーの総面積に対して1%以上である、前記(1)記載の強化繊維基材。
(3)前記強化繊維基材の面積に対する、前記熱融着性バインダーの総面積の比率が5~70%の範囲である、(1)又は(2)に記載の強化繊維基材。
(4)さらに、前記強化繊維基材を構成する強化繊維の平均直径の3000倍以下のふるい径を有する熱融着性バインダーが配置された、(1)~(3)のいずれかに記載の強化繊維基材。
(5)表面に、実質的に同一な熱融着性バインダーの集合パターンが繰り返し配置されている強化繊維基材。
バインダー透過シートの表面に粉末状バインダーを配する工程と、
バインダー透過孔に粉末状バインダーを貯留する工程と、
バインダー透過シートを強化繊維基材のバインダー塗布面から相対的に離間させる工程と、
この離間時に、透過孔に貯留されている粉末状バインダーを強化繊維基材のバインダー塗布面に転移させる工程と
を有する、表面に熱融着性バインダーが配置された強化繊維基材の製造方法。
(8)さらに、上記の転移された粉末状バインダーを強化繊維基材上に融着させる工程を有する、(7)記載の強化繊維基材の製造方法。
(9)前記透過パターンが、ドット及び/又はライン形状を有する、前記(7)又は(8)記載の強化繊維基材の製造方法。
(10)所定の透過パターンを有する前記バインダー透過シートを連続的に用いて、実質的に同一な熱融着性バインダーの集合パターンを基材上に繰り返し配置させる、前記(7)~(9)のいずれかに記載の強化繊維基材の製造方法。
(11)ヘラによるバインダー透過シートへの押付力を調整することにより、1ドット状又は1ライン状のバインダーの塗布量を制御することを含む、前記(9)又は(10)記載の強化繊維基材の製造方法。
(12)バインダー透過シートの開口率を調整することにより、1ドット状又は1ライン状のバインダーの塗布量を制御することを含む、前記(9)~(11)のいずれかに記載の強化繊維基材の製造方法。
積層された複数枚の強化繊維基材を二以上の賦形金型間に挟んで加熱加圧して、各強化繊維基材を賦形すると同時にバインダーを融着させる工程と
を有する、賦形布帛の製造方法。
また、本発明の強化繊維基材は、上記の強化繊維を含む、織物、編物、ノンクリンプファブリック、不織布などの布帛から構成される。
この熱融着性バインダーは、常温で固体である樹脂であり、熱硬化性樹脂や熱可塑性樹脂から選択して用いることができる。
熱硬化性樹脂としては、例えば、不飽和ポリエステル樹脂、エポキシ樹脂、ビニルエステル樹脂、フェノール樹脂、エポキシアクリレート樹脂、ウレタンアクリレート樹脂、フェノキシ樹脂、アルキド樹脂、ウレタン樹脂、マレイミド樹脂、シアネート樹脂などが挙げられる。
熱可塑性樹脂としては、例えば、ポリオレフィン系樹脂、アクリル樹脂、ポリアミド系樹脂、ポリエステル系樹脂、ポリフェニレンサルファイド樹脂、ポリエーテルケトン樹脂、ポリエーテルスルフォン樹脂、芳香族ポリアミド樹脂などが挙げられる。
上記の樹脂は、RTMにおいて使用するマトリックス樹脂との相溶性等を考慮して、一種以上を適宜選択して使用することができる。
この熱融着性バインダーは、例えば、粉体の集合体が基材上に所定の形状に配置された状態であっても良いが、熱融着性バインダーの形状安定性や、強化繊維基材の積層時の作業性等に優れることから、所定の形状に一体化された状態で、強化繊維基材上に接着されているのが好ましい。上記のように粉体の熱融着性バインダーが基材上に配置されている場合には、この状態で、粉体の熱融着性バインダーを加熱することで溶融一体化させ、これを基材上に固定させることができる。
一方、強化繊維基材へのバインダー塗布の作業性や本発明の強化繊維基材の生産性を考慮する場合においては、本発明を構成する熱融着性バインダーの厚みは、600μm以下とするのが好ましく、300μm以下とするのがより好ましい。
強化繊維基材上に、バインダー透過孔による透過パターンを有し所要の厚みを有するバインダー透過シートを配する工程、
バインダー透過シートの表面に粉末状バインダーを配する工程、
バインダー透過孔に粉末状バインダーを貯留する工程、
バインダー透過シートを強化繊維基材のバインダー塗布面から相対的に離間させる工程と、
この離間時に、透過孔に貯留されている粉末状バインダーを強化繊維基材のバインダー塗布面に転移させる工程。
また、上記の工程を採用することによって、バインダー透過シートに形成されるパターンにおけるバインダー透過孔の配置密度を適宜変更できるとともに、粉末バインダーの形状と寸法を設計通りに正確に再現させることができるため、賦形布帛の賦形形状やRTM時におけるマトリックス樹脂含浸性を考慮したバインダー塗布密度の調整が可能となる。
ここでメッシュ織物を用いた場合のメッシュの目の大きさは、特に限定されるものではないが、粉末状バインダーのメッシュへの透過性の点から、100~1000μmの範囲とするのが好ましい。
この加熱加圧条件は、賦形布帛の形状やバインダーの種類等に応じて適宜選択することができる。
このRTMの条件やマトリックス樹脂の種類は、繊維強化プラスチック構造体の形状や用途に応じて適宜選択することができる。
(実施例1)
炭素繊維ノンクリンプファブリック(TK Industries社製、TKI300B127T、炭素繊維の平均直径:約7μm)に、粉体バインダー(Hexion社製Epikote 05390)を塗布するため、Φ6.2mm、ピッチ10mm、正方配列に開口するスクリーンを使用した。
ノンクリンプファブリックにスクリーンを乗せて密着させ、スクリーン上の一辺端部にバインダーを貯留し、ゴムヘラによって、貯留したバインダーを対向する辺へ、移動させるスクリーン印刷方式により、スクリーンの開口部を通して粉体バインダーをノンクリンプファブリックに転写させ、スクリーンを外して、バインダーを塗布した。
さらに、赤外線を照射してバインダーを溶融させた後に冷却することで、これを定着させ、ふるい径5.7~6.3mmのドット状のバインダーの面積率が26%、投影面積円相当径が1.5~1.8mmの微小ドット状のバインダーの面積率1.0%(熱融着性バインダーの総面積に対して3.7%)である強化繊維基材が得られた。
また、この強化繊維基材を複数枚準備し、これらのバインダー定着側が同一面を向くように積層した後に賦形金型間に挟んで加熱加圧することで、賦形布帛を得た。この賦形布帛は、充分な層間の接着強度を有しており、形状安定性に優れていた。
スクリーン印刷方式を行わず、ノンクリンプファブリック上に粉体バインダーを散布した以外は、実施例1と同様な条件で、ノンクリンプファブリックの面積に対するバインダーの総面積の比率が27%である強化繊維基材を製造した。
この強化繊維基材においては、投影面積円相当径が0.9~1.7mmの微小ドットの強化繊維基材に対する面積率は、12.6%(熱融着性バインダーの総面積に対して46.7%)であった。
また、この強化繊維基材を複数枚準備し、これらのバインダー定着側が同一面を向くように積層した後に賦形金型間に挟んで加熱加圧することで賦形布帛を得たが、この賦形布帛は、形状安定性に劣っていた。
1’ (バインダー塗布後の)2枚の強化繊維基材積層体
4 (バインダー塗布後の)多数の繊維強化基材積層体
5 上型
6 下型
10 (切り出した)強化繊維基材
11 粉末状バインダー
12 バインダー透過シート
13 枠体
13a~13d 第1~第4枠材
14 ヘラ
15 バインダー透過孔
Claims (14)
- 表面に熱融着性バインダーが複数配置された強化繊維基材であって、該強化繊維基材を構成する強化繊維の平均直径の300倍未満の投影面積円相当径を有する熱融着性バインダーの面積の合計が、該表面に配置された熱融着性バインダーの総面積に対して10%以下である強化繊維基材。
- 前記平均直径の300倍未満の投影面積円相当径を有する熱融着性バインダーの面積の合計が、前記熱融着性バインダーの総面積に対して1%以上である、請求項1記載の強化繊維基材。
- 前記強化繊維基材の面積に対する、前記熱融着性バインダーの総面積の比率が5~70%の範囲である、請求項1又は2に記載の強化繊維基材。
- さらに、前記強化繊維基材を構成する強化繊維の平均直径の3000倍以下のふるい径を有する熱融着性バインダーが配置された、請求項1~3のいずれかに記載の強化繊維基材。
- 表面に、実質的に同一な熱融着性バインダーの集合パターンが繰り返し配置されている強化繊維基材。
- 実質的に同一な熱融着性バインダーの集合パターンを表面に有する複数の強化繊維基材が積層された賦形布帛。
- 強化繊維基材上に、バインダー透過孔による透過パターンを有し所要の厚みを有するバインダー透過シートを配する工程と、
バインダー透過シートの表面に粉末状バインダーを配する工程と、
バインダー透過孔に粉末状バインダーを貯留する工程と、
バインダー透過シートを強化繊維基材のバインダー塗布面から相対的に離間させる工程と、
この離間時に、透過孔に貯留されている粉末状バインダーを強化繊維基材のバインダー塗布面に転移させる工程、
を有する、表面に熱融着性バインダーが配置された強化繊維基材の製造方法。 - さらに、上記の転移された粉末状バインダーを強化繊維基材上に融着させる工程を有する、請求項7記載の強化繊維基材の製造方法。
- 前記透過パターンが、ドット及び/又はライン形状を有する、請求項7又は8に記載の強化繊維基材の製造方法。
- 所定の透過パターンを有する前記バインダー透過シートを連続的に用いて、実質的に同一な熱融着性バインダーの集合パターンを基材上に繰り返し配置させる、請求項7~9のいずれかに記載の強化繊維基材の製造方法。
- ヘラによるバインダー透過シートへの押付力を調整することにより、1ドット状又は1ライン状のバインダー塗布量を制御することを含む、請求項9又は10記載の強化繊維基材の製造方法。
- バインダー透過シートの開口率を調整することにより、1ドット状又は1ライン状のバインダー塗布量を制御することを含む、請求項9~11のいずれかに記載の強化繊維基材の製造方法。
- 請求項7~12のいずれかに記載の製造方法によって得た複数枚の強化繊維基材をバインダー配置面が同一面を向くように積層する工程と、
積層された複数枚の強化繊維基材を二以上の賦形金型間に挟んで加熱加圧して、各強化繊維基材を賦形すると同時にバインダーを融着させる工程と、
を有する、賦形布帛の製造方法。 - 請求項13に記載の製造方法により得た前記賦形布帛にマトリックス樹脂を含浸・硬化させる、繊維強化プラスチック構造体。
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CN201680049502.0A CN107921664A (zh) | 2015-08-31 | 2016-08-26 | 增强纤维基材及其制造方法、赋形布帛及其制造方法、以及纤维增强塑料结构体 |
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