WO2018181254A1 - プリプレグおよび繊維強化複合材料 - Google Patents
プリプレグおよび繊維強化複合材料 Download PDFInfo
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- WO2018181254A1 WO2018181254A1 PCT/JP2018/012307 JP2018012307W WO2018181254A1 WO 2018181254 A1 WO2018181254 A1 WO 2018181254A1 JP 2018012307 W JP2018012307 W JP 2018012307W WO 2018181254 A1 WO2018181254 A1 WO 2018181254A1
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- prepreg
- epoxy resin
- fiber
- composite material
- reinforced composite
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- C—CHEMISTRY; METALLURGY
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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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Definitions
- the present invention relates to a prepreg and a fiber reinforced composite material.
- Fiber reinforced composite materials made of reinforced fibers such as carbon fibers and glass fibers and matrix resins are lightweight but have excellent mechanical properties such as strength and rigidity, heat resistance, and corrosion resistance. It has been applied to many fields such as automobiles, railway vehicles, ships, civil engineering and sports equipment. Among them, members for aircraft such as general passenger aircraft and regional jets and members for spacecraft such as artificial satellites, rockets, and space shuttles are required to have particularly excellent mechanical characteristics and heat resistance. Therefore, in such applications, lightweight and highly rigid carbon fibers are often used as reinforcing fibers, and thermosetting resins such as epoxy resins with excellent heat resistance, elastic modulus, and chemical resistance are used as matrix resins. It is often done.
- the main cause of the deterioration of the mechanical properties of the fiber reinforced composite material is the presence of voids intervening inside the fiber reinforced composite material.
- damage such as cracks and peeling is likely to occur, which lowers the mechanical strength and rigidity. For this reason, many studies have been made on materials / molding techniques for suppressing this void for a long time.
- an autoclave molding method as a molding method that can particularly suppress the generation of voids.
- the resin can be heat-cured while applying pressure, the size of the void can be reduced.
- the vaporization of the volatile component contained in the matrix resin can be suppressed, the amount of voids generated can be significantly suppressed.
- a pressure vessel autoclave
- Patent Document 1 discloses that when the reinforcing fiber layer is impregnated with the matrix resin, by suppressing the impregnation of the resin and interposing the unimpregnated portion inside the prepreg, There has been proposed a partially impregnated prepreg provided with a gap for exhausting biting air. Using this method, even when molding is performed in an atmospheric pressure environment that uses only a vacuum pump and an oven and does not use an autoclave, the volatile matter and air trapped that cause the generation of voids through the voids are removed. Therefore, a fiber-reinforced composite material with few voids can be manufactured in a short time.
- Patent Document 2 discloses a high-strength interlayer that dramatically increases impact resistance by localizing a high-toughness thermoplastic resin between fiber layers as a fiber-reinforced composite material for aircraft / spacecraft.
- the technology has been proposed. In actual operation of aircraft and spacecraft, impact damage such as collision with birds and spears becomes a problem, but by using the above-mentioned technology of interlayer toughening, the impact strength of fiber reinforced composite materials is dramatically increased. Can be increased.
- thermoplastic resin disposed between the layers described in Patent Document 2 is generally in a solid or high viscosity state at the molding temperature. Therefore, the movement of the matrix resin (hereinafter referred to as a flow) is less likely to occur during molding, and the resin is easily cured without impregnating the resin in the voids contained in the prepreg laminate, resulting in frequent voids. It was.
- an object of the present invention is a prepreg suitable for producing a fiber-reinforced composite material in a short time without using an autoclave, in which generation of voids is suppressed and excellent resistance to resistance. It is an object to provide a prepreg excellent in handling property, and to provide a fiber reinforced composite material using the fiber reinforced composite material exhibiting impact properties.
- the inventors of the present invention have intensively studied to solve such problems, and localize the unimpregnated portion of the prepreg reinforcing fiber layer on one side of the prepreg, particularly on the side on which the thermoplastic resin is disposed.
- the continuity of this non-impregnated part has been dramatically improved, and it has been found that air trapped during lamination and volatile components contained in the matrix resin can be efficiently removed out of the prepreg laminate. It was.
- the present invention employs the following means.
- the reinforcing fiber [A] arranged in a layer is partially impregnated with the epoxy resin composition containing the epoxy resin [B] and the curing agent [C], and the impregnation ratio ⁇ is 30.
- 95% of the thermoplastic resin [D] insoluble in the epoxy resin [B] is unevenly distributed on the surface of one side of the prepreg, and the reinforcing fiber [A] is not impregnated with the epoxy resin composition.
- the localization parameter ⁇ defining the degree of localization is in the range of 0.10 ⁇ ⁇ 0.45 It is a prepreg.
- the fiber-reinforced composite material of the present invention is obtained by curing the prepreg.
- the prepreg of the present invention is a prepreg suitable for producing a fiber-reinforced composite material in a short time without using an autoclave, and is a fiber that suppresses generation of voids and exhibits excellent impact resistance. It is a prepreg which can obtain a reinforced composite material and has excellent handling properties.
- the fiber reinforced composite material of the present invention is a fiber reinforced composite material in which generation of voids is suppressed and excellent impact resistance is expressed.
- the reinforcing fibers [A] arranged in layers are partially impregnated with an epoxy resin composition containing an epoxy resin [B] and a curing agent [C], and the impregnation ratio ⁇ is 30 to 95. %,
- the thermoplastic resin [D] insoluble in the epoxy resin [B] is unevenly distributed on the surface of one side of the prepreg, and the unimpregnated portion of the epoxy resin composition is present in the reinforcing fiber [A] layer.
- a prepreg in which the thermoplastic resin [D] is localized on the side where the thermoplastic resin [D] is unevenly distributed and the localization parameter ⁇ defining the degree of localization is in the range of 0.10 ⁇ ⁇ 0.45. is there.
- the reinforcing fiber [A] used in the present invention may be any fiber such as glass fiber, Kevlar fiber, carbon fiber, graphite fiber, or boron fiber. Of these, carbon fibers that are excellent in specific strength and specific elastic modulus are preferable in order to obtain a particularly high lightening effect.
- the reinforcing fibers [A] are continuous fibers arranged in one direction.
- a continuous fiber By using a continuous fiber, it becomes possible to express a high mechanical strength as compared to a fiber cut short.
- a fiber-reinforced composite material having a high fiber content and excellent strength and rigidity can be obtained.
- “arranged in one direction” means that the surface of the prepreg is observed with an optical microscope, the orientation angle of each fiber is ⁇ , and the average value is ⁇ , and ⁇ 10 ° ⁇ ⁇ This means that 90% or more of the fibers satisfying ⁇ + 10 ° are present.
- the “continuous fiber” in the present invention is a reinforcing fiber having a length capable of expressing high strength, and specifically means a reinforcing fiber of 10 cm or more.
- the continuous fibers arranged in one direction include unidirectional fabrics in which reinforcing fibers are sewn together in the width direction using auxiliary yarns.
- the reinforcing fiber [A] is in a woven form.
- the base material itself is easily deformed in the in-plane direction, and the base material is easily shaped into a shape having three-dimensional unevenness.
- the woven form include bi-directional woven fabric, multi-axial woven fabric, knitted fabric, braided string and the like.
- the reinforcing fiber [A] is a sheet-like short fiber substrate.
- the short fiber base material is more easily extended than the textile base material, and the base material is easily formed into a three-dimensionally more complicated shape.
- Examples of the short fiber base material include a nonwoven fabric, a mat, a sheet molding compound material, and the like.
- the fiber length of the reinforcing fiber included in this embodiment is 12 mm or more, preferably 25 mm or more when the mechanical strength is given priority. This is because high mechanical strength is easily exhibited as compared to reinforcing fibers of less than 12 mm.
- these preferable aspects can be suitably selected according to the application and use environment.
- the epoxy resin [B] included in the present invention may be any epoxy resin as long as it has one or more glycidyl groups, but preferably has two or more glycidyl groups in one molecule.
- the glass transition temperature of a cured product obtained by heating and curing a mixture with a curing agent described later (hereinafter referred to as an epoxy resin composition) is glycidyl group. It becomes high compared with the cured
- epoxy resin examples include bisphenol A type epoxy resins, bisphenol F type epoxy resins, bisphenol AD type epoxy resins, bisphenol S type epoxy resins, and other bisphenol type epoxy resins, and tetrabromobisphenol A diglycidyl ether.
- Brominated epoxy resins such as, epoxy resins having a biphenyl skeleton, epoxy resins having a naphthalene skeleton, epoxy resins having a dicyclopentadiene skeleton, phenol novolac epoxy resins, cresol novolac epoxy resins and other novolac epoxy resins, diaminodiphenylmethane Type epoxy resin, diaminodiphenylsulfone type epoxy resin, aminophenol type epoxy resin, metaxylenediamine type epoxy resin, 1 3-bis-aminomethyl cyclohexane type epoxy resin, glycidyl amine type epoxy resins such as isocyanurate type epoxy resins.
- an epoxy resin having three or more glycidyl groups in one molecule is preferable because it can express a higher glass transition temperature and elastic modulus.
- epoxy resins may be used alone or as a mixture of a plurality of epoxy resins.
- a mixture of a plurality of epoxy resins for example, mixing an epoxy resin exhibiting fluidity and an epoxy resin not exhibiting fluidity at any temperature below the curing start temperature of the epoxy resin composition, It is effective for controlling the fluidity of the matrix resin during prepreg molding. If the fluidity is not controlled, for example, if the fluidity shown until the matrix resin gels during prepreg molding is large, the orientation of the reinforcing fibers may be disturbed, or the matrix resin may be removed from the reinforcing fiber layer. By flowing out, the fiber mass content becomes excessively low, and the mechanical properties of the resulting fiber-reinforced composite material may be lowered.
- combining a plurality of epoxy resins exhibiting various viscoelastic behaviors at an arbitrary temperature is also effective for making the tack (adhesiveness) and draping property of the obtained prepreg appropriate.
- thermoplastic resin compatible with the epoxy resin into the epoxy resin [B].
- mixing a compatible thermoplastic resin with the epoxy resin [B] makes it possible to optimize the tack of the resulting prepreg, to control the fluidity of the matrix resin during prepreg heat curing, and to obtain the fiber-reinforced composite material obtained.
- a thermoplastic resin a thermoplastic resin composed of a polyaryl ether skeleton is preferable.
- polysulfone, polyphenylsulfone, polyethersulfone, polyetherimide, polyphenylene ether, polyetheretherketone, polyetherethersulfone, etc. Is a candidate.
- Thermoplastic resins composed of these polyaryl ether skeletons may also be used alone or in combination as appropriate.
- polyethersulfone and polyetherimide can be preferably used because they can impart toughness without deteriorating the heat resistance and mechanical properties of the resulting fiber-reinforced composite material.
- thermoplastic resin composed of a polyaryl ether skeleton it is effective to appropriately select the type of terminal functional group in order to control the affinity and reactivity with the epoxy resin.
- the terminal functional group examples include a primary amine, a secondary amine, a hydroxyl group, a carboxyl group, a thiol group, an acid anhydride, a halogen group (chlorine, bromine), and the like.
- a halogen group chlorine, bromine
- the curing agent [C] included in the present invention may be any compound having an active group capable of undergoing a crosslinking reaction with a glycidyl group.
- a compound having an amino group, an acid anhydride group or an azide group is suitable as the curing agent [C].
- Specific examples of the curing agent [C] include dicyandiamide, diaminodiphenylmethane, various isomers of diaminodiphenylsulfone, aminobenzoic acid esters, various acid anhydrides, phenol novolac resin, cresol novolac resin, polyphenol compound, imidazole derivative.
- a cured resin having good heat resistance can be obtained by using an aromatic diamine as the curing agent [C].
- various isomers of diaminodiphenylsulfone are most preferable because a cured resin having good heat resistance can be obtained.
- the addition amount of the aromatic diamine curing agent is preferably such that the active hydrogen in the aromatic amine compound is in the range of 0.7 to 1.3 per glycidyl group in the epoxy resin composition. More preferably, the amount is 0.8 to 1.2.
- the active hydrogen refers to a hydrogen atom bonded to nitrogen, oxygen, or sulfur of an amino group, a hydroxyl group, or a thiol group in an organic compound.
- a curing aid may be included in the curing agent [C] in order to develop high heat resistance and water resistance while curing at a relatively low temperature.
- the curing aid does not react directly with the glycidyl group of the epoxy resin [B] to form a crosslinked structure, but promotes a crosslinking reaction between the epoxy resin [B] and the curing agent [C] as a catalyst. It is.
- curing aids examples include 3-phenol-1,1-dimethylurea, 3- (3-chlorophenyl) -1,1-dimethylurea, 3- (3,4-dichlorophenyl) -1,1-dimethylurea And urea compounds such as 2,4-toluenebisdimethylurea and 2,6-toluenebisdimethylurea).
- the viscosity of the epoxy resin composition (which may contain a curing aid) composed of these epoxy resins and a curing agent is low and a problem occurs in the handling property of the prepreg, the epoxy resin composition is pre-reacted. It is also effective to increase the viscosity. As the viscosity increases, appropriate tackiness can be imparted to the prepreg, and handling properties can be improved, or the storage stability of the prepreg can be improved.
- thermoplastic resin [D] included in the present invention is insoluble in the epoxy resin [B] and is disposed on the surface of the prepreg.
- the thermoplastic resin [D] is unevenly distributed between the fiber layer and the fiber layer.
- the form of the thermoplastic resin may be any form as long as it can be arranged in layers, and may be any form such as particles, short fiber mats, non-woven fabrics, or films.
- thermoplastic resin [D] used in the present invention may or may not have crystallinity.
- specific examples of the thermoplastic resin include polyamide, polycarbonate, polyacetal, polyphenylene oxide, polyphenylene sulfide, polyarylate, polyester, polyamideimide, polyimide, polyetherimide, polyimide having a phenyltrimethylindane structure, polysulfone, and polyethersulfone.
- Polyether ketone, polyether ether ketone, polyaramid, polyether nitrile, and polybenzimidazole are most preferred because it greatly improves impact resistance due to excellent toughness.
- semi-IPN polymer interpenetrating network structure
- polyamide 12 polyamide 6, polyamide 11, polyamide 6/12 copolymer or an epoxy compound described in Example 1 of JP-A-1-104624.
- the polyamide fine particles have particularly good adhesive strength with the epoxy resin. Therefore, the delamination strength of the fiber-reinforced composite material at the time of falling weight impact is increased, and the impact resistance is improved, which is preferable.
- the shape thereof may be spherical, non-spherical, porous, whisker-like, or flake-like.
- spherical particles it is most preferable to use spherical particles in order to ensure the impregnation property of the epoxy resin to the reinforcing fiber and to reduce the effect of stress concentration induced by the difference in rigidity between the thermoplastic resin and the matrix resin.
- the average particle diameter is preferably in the range of 3 ⁇ m to 40 ⁇ m, and more preferably in the range of 5 ⁇ m to 30 ⁇ m.
- the shape may be short fibers or long fibers.
- short fibers a method of using the fibers in the same manner as the particles or a method of processing into a mat is possible as disclosed in JP-A-2-69566.
- long fibers a method of arranging long fibers parallel to the surface of the prepreg as shown in JP-A-4-292634, or a method of randomly arranging fibers as shown in International Publication No. 94/016003 Can be used.
- the fiber may be processed and used as a sheet-type substrate such as a woven fabric as disclosed in JP-A-2-32843, or a non-woven material or a knitted fabric as disclosed in WO94 / 016003. it can.
- a method in which short fiber chips, chopped strands, milled fibers, and short fibers are spun into a yarn and then arranged in parallel or randomly to form a woven or knitted fabric can be used.
- thermoplastic resin [D] is not substantially dissolved in the epoxy resin when the epoxy resin in which the thermoplastic resin [D] is dispersed is heated and cured. . More specifically, for example, using a transmission electron microscope, the thermoplastic resin [D] and the matrix resin are not substantially reduced from the original size in the cured epoxy resin. It means that it can be observed with a clear interface.
- the prepreg of the present invention is characterized in that the thermoplastic resin [D] insoluble in the epoxy resin [B] is unevenly distributed on one surface of the prepreg.
- the resin mass content in the prepreg of the present invention is preferably in the range of 25 to 45%.
- the resin mass content means that resin components (epoxy resin [B], curing agent [C], thermoplastic resin [D] and other additives) excluding reinforcing fiber [A]) are contained in the prepreg. Refers to the mass ratio.
- the resin mass content By setting the resin mass content to 45% or less, the advantage of the fiber-reinforced composite material, which is excellent in specific strength and specific elastic modulus, can be easily obtained. In view of these, a more preferable range of the resin mass content is 30 to 36%.
- the prepreg of the present invention is a prepreg in which the reinforcing fiber is partially impregnated with the epoxy resin composition.
- the partially impregnated prepreg means that the reinforcing fiber layer of the prepreg includes a region not impregnated with resin (unimpregnated portion).
- the impregnation ratio ⁇ of the epoxy resin composition in the prepreg is 30 to 95%, preferably 50 to 95%, more preferably 60 to 90%.
- the frequency is reduced by increasing the impregnation rate ⁇ of the epoxy resin composition in the prepreg. be able to.
- the impregnation rate 30% or more preferably 50% or more, more preferably 60% or more, a prepreg excellent in handling properties can be obtained.
- the impregnation rate ⁇ of the epoxy resin composition in the prepreg is (the number of reinforcing fibers present per unit width to which no epoxy resin composition is adhered) / (total number of reinforcing fibers present per unit width) Number).
- the prepreg is cut with a knife, and the fracture surface is observed with an SEM.
- the cutting direction of the prepreg is a surface where the number of reinforcing fibers included in the cut surface is the largest. For example, in the case of a prepreg in which reinforcing fibers are arranged in one direction, the direction orthogonal to the fiber is taken as the cut surface.
- the prepreg is divided into four cross sections (0 degree direction, 45 degree direction, 90 degree direction, 45 degree intervals, 135-degree direction), and a cross section in which the number of carbon fibers included in each cross section is the largest is adopted.
- the observation magnification of the SEM is set to 500 times, images having an imaging region that does not overlap each other are acquired for a width of 1 mm, the impregnation rate ⁇ of the prepreg is measured for each image, and the average value is calculated.
- thermoplastic resin [D] insoluble in the epoxy resin [B] is unevenly distributed on the surface of one side of the prepreg, and in the reinforced fiber [A] layer, the unimpregnated portion of the epoxy resin composition Is characterized by being localized on the side where the thermoplastic resin [D] is unevenly distributed.
- FIGS. 1A and 1B a schematic diagram of a cross section of a conventional vacuum pressure forming prepreg is shown in FIGS. 1A and 1B, and a schematic diagram of a cross section of the prepreg of the present invention is shown in FIG. Each is shown.
- description will be made with reference to these drawings.
- an interlayer forming layer 3 containing an epoxy resin composition 1 and a thermoplastic resin 2 insoluble in an epoxy resin is formed on both surfaces of the prepreg.
- an aggregate of reinforcing fibers to which the epoxy resin composition is not attached that is, an unimpregnated layer 7.
- the unimpregnated layer 7 functions as a flow path for removing volatile components and entrained air, a fiber-reinforced composite material with less voids can be obtained.
- the resin impregnation distance (from the surface of the reinforcing fiber layer to the resin) is increased depending on the location, for example, due to the density of the reinforcing fibers or unevenness of the wetting between the reinforcing fibers and the resin The distance to the impregnated part tip) is different.
- the epoxy resin composition is impregnated from both surfaces of the prepreg, the epoxy resin composition of the interlayer forming layer on both surfaces as shown in FIG. Things are connected and the continuity of the unimpregnated layer 7 is lost. For this reason, the function as a flow path for removing the volatile matter in the unimpregnated layer is lost, which causes a void.
- the thermoplastic resin 2 that is insoluble in the epoxy resin is unevenly distributed on the one-side surface of the prepreg.
- uneven distribution refers to a state in which substantially all the thermoplastic resin 2 insoluble in the epoxy resin is present on one side of the prepreg. Specifically, it means that a region of the thermoplastic resin 2 is extracted from the cross-sectional image of the prepreg, and 90% or more of the total area is present on one side of the prepreg.
- the method for obtaining a cross-sectional image of the prepreg is as follows. First, after the prepreg is heated to 180 ° C.
- the cured prepreg is embedded in the resin and polished, so that the cured prepreg Get a cross section.
- a region corresponding to a width of 0.2 mm is observed on the cross section of the prepreg after curing under a condition of 1000 times with an optical microscope.
- the interlayer formation layer 3 containing the thermoplastic resin 2 insoluble in the epoxy resin suppresses resin impregnation into the reinforcing fiber layer and smoothes the tip of the resin impregnated portion. Therefore, the resin surface of the impregnated portion of the interlayer forming layer 3 containing the thermoplastic resin 2 is relatively smooth, and even if the impregnation distance of the epoxy resin layer 4 on which the thermoplastic resin 2 is not arranged varies from place to place, the volatile matter It is possible to ensure the continuity of the non-impregnated layer for removing.
- a plurality of methods are conceivable as means for suppressing the resin impregnation of the reinforcing fiber layer in the interlayer forming layer 3 containing the thermoplastic resin 2 insoluble in the epoxy resin.
- the viscosity of the interlayer forming layer is increased, and resin impregnation into the reinforcing fiber layer is suppressed.
- the prepreg of the present invention shortens the impregnation distance on the side containing the thermoplastic resin 2 insoluble in the epoxy resin, and the epoxy resin layer on the side not containing the thermoplastic resin 2 insoluble in one epoxy resin
- the unimpregnated layer 7 is not localized in the center of the reinforcing fiber layer 6 but is localized on the side where the thermoplastic resin 2 insoluble in the epoxy resin is disposed.
- the localization parameter ⁇ is defined by the following procedure.
- the calculation method of the localization parameter ⁇ will be described with reference to the schematic diagrams of the prepreg cross sections of FIGS.
- the side on which the thermoplastic resin is unevenly distributed is defined as the upper side
- the side not including the thermoplastic resin is defined as the lower side.
- a region corresponding to a width of 1 mm of the prepreg cross-sectional image is extracted and is a line perpendicular to the reinforcing fiber sheet, and is a line that divides the region into 11 equal parts in the width direction ( Draw 10 equal lines 8).
- the y coordinate of the end portion of the reinforcing fiber layer 6 on the epoxy resin layer 4 side is calculated on the bisector, and this is the lower end of the reinforcing fiber layer. Let it be a part y coordinate.
- the lower end y-coordinate is calculated for 10 equal lines 8, and the average value is set to 0 on the y-coordinate axis.
- the average value of the upper end y-coordinate is obtained by the same procedure, and this y-coordinate is set as T.
- T corresponds to the thickness of the reinforcing fiber layer 6.
- H3 the average value thereof is defined as H3.
- H4 the y coordinate of the upper end portion of the reinforcing fiber in the unimpregnated layer
- H4 is calculated from the average of the remaining nine unimpregnated fiber coordinates.
- H3 which is an average value of y-coordinates of the unimpregnated reinforcing fiber located on the end portion on the epoxy resin layer 4 side on the equisegmentation line 8, and the equisegmentation line 8
- H4 which is the average value of the y-coordinates of the unimpregnated reinforcing fiber located at the end of the upper interlayer forming layer 3 side matches.
- H5 0.5
- H2 0, and ⁇ is 0.5.
- the localization parameter ⁇ is 0.10 ⁇ ⁇ 0.45, and preferably 0.20 ⁇ ⁇ 0.45.
- the prepreg of the present invention preferably has a reinforcing fiber amount per unit area of 30 to 600 g / m 2 .
- the amount of the reinforcing fiber is 30 g / m 2 or more, it is not necessary to increase the number of laminated layers in order to obtain a predetermined thickness when forming the fiber-reinforced composite material, and the work load is easily reduced. Further, when the amount of reinforcing fiber is 600 g / m 2 or less, the prepreg drapability is easily improved.
- the basis weight is small in order to shorten the impregnation distance, but if it is thin, it is easily affected by the density of the fibers. More preferably, it is in the range of ⁇ 300 g / m 2 .
- the prepreg of the present invention can remove volatile components in the prepreg more efficiently by ensuring continuity from the vacuum suction part to the unimpregnated part of the prepreg.
- the simplest method for ensuring the continuity of the unimpregnated portion is to reduce the degree of impregnation ⁇ and increase the number of unimpregnated portions.
- the measurement for calculating the permeation coefficient K in the in-plane direction in the present invention is measured using the air flow rate measuring method schematically shown in FIG. Details of the measurement method are described below.
- a prepreg laminate 9 in which ten layers of strip-shaped prepregs (fiber orientation direction 100 mm, fiber vertical direction 50 mm) are laminated, only the both ends of the prepreg in the fiber orientation direction are opened, and the prepreg thickness direction is determined by the sealant 10. , And shut off the air permeability of the side.
- the prepreg laminate 9 and the sealant 10 are sealed with a cover film 11 and a metal plate 12. An air flow path is secured along the glass tape 13 at the end of the prepreg laminate 9.
- the vent 15 is opened to atmospheric pressure (the pressure of the pressure gauge 16 on the vent 15 side is set to Pa (unit: Pa)), and the opposite side is evacuated by the vacuum pump 17 to the vacuum pressure environment (the pressure gauge 16 on the vacuum pump 17 side). Is set to Pv (unit: Pa). At this time, a pressure difference is generated on both sides of the prepreg, but the penetration coefficient K (unit: m 2 ) in the in-plane direction of the prepreg is defined by the following equation (1).
- ⁇ is the air viscosity (unit: Pa ⁇ s)
- L is the prepreg length (unit: m)
- Ap is the prepreg cross-sectional area (unit: m 2 )
- Qa is the air flow rate measured by the air flow meter 14. (Unit: m 3 / s).
- the orientation direction in the present invention means a cross section in the ⁇ direction when the surface of the prepreg is observed with an optical microscope, the orientation angle of each fiber is ⁇ , and the average value is ⁇ .
- the average value ⁇ arbitrary 30 fibers are selected from the fibers observed by the optical microscope, and the average value of the orientation angles is used.
- a plurality of methods can be considered as a method for producing the prepreg of the present invention.
- the simplest method for producing the prepreg of the present invention is a hot melt method in which an epoxy resin film is superimposed on the surface of a reinforcing fiber sheet arranged in a sheet shape and is pressed / heat impregnated. For example, by sandwiching an epoxy resin film containing a thermoplastic resin from one side and an epoxy resin film containing only an epoxy resin composition from the other side on the surface of a reinforcing fiber sheet arranged in a sheet shape, and passing it through a heating impregnation roll The prepreg of the present invention can be obtained.
- an epoxy resin film containing only an epoxy resin composition is provided on one side of the reinforcing fiber sheet surface arranged on the sheet, and an epoxy resin film containing only the epoxy resin composition is provided on the other surface. It is arrange
- the fiber-reinforced composite material of the present invention is obtained by curing the prepreg of the present invention. That is, the fiber-reinforced composite material of the present invention can be produced by heat-curing the prepreg of the present invention or a laminate thereof.
- the prepreg of the present invention is suitable for vacuum pressure molding, it can also be used as a prepreg in which voids hardly occur in autoclave molding and press molding.
- the prepreg of the present invention is cured by heating in an oven, for example, it is possible to obtain a fiber-reinforced composite material with less voids by using the following molding method.
- a prepreg laminate obtained by laminating a single-layer prepreg or a plurality of prepregs is wrapped in a bag having an internal pressure of 11 kPa or less, kept at a temperature of 20 to 70 ° C. to remove volatile components, and the pressure is reduced to 11 kPa or less.
- the temperature is raised to the curing temperature while maintaining.
- the removal of the volatile matter is preferably performed under the condition that the pressure is 0.1 kPa to 11 kPa, and more preferably under the condition of 0.1 kPa to 7 kPa.
- the internal pressure By setting the internal pressure to 11 kPa or less, it becomes easy to sufficiently remove volatile components in the prepreg, and voids are hardly generated in the obtained fiber-reinforced composite material.
- the resin is filled in the non-impregnated portion, and then the resin curing temperature (130 ° C. 200 ° C.) and the resin is preferably cured.
- the unit “part” of the composition ratio means part by mass unless otherwise specified.
- Various characteristics were measured in an environment at a temperature of 23 ° C. and a relative humidity of 50% unless otherwise specified.
- Carbon fiber Carbon fiber (Product name: “Torayca®” T800S-24K-10E, 24,000 filaments, tensile strength 5.9 GPa, tensile elastic modulus 290 GPa, tensile elongation 2.0%, manufactured by Toray Industries, Inc.) .
- Epoxy resin [Epoxy resin] ⁇ Bisphenol A type epoxy resin (Product name: “jER (registered trademark)” 825, manufactured by Mitsubishi Chemical Corporation) Tetraglycidyldiaminodiphenylmethane (Product name: “Araldite (registered trademark)” MY721, manufactured by Huntsman Advanced Materials) Bisphenol F type epoxy (product name: “Epicron (registered trademark)” 830, manufactured by DIC Corporation).
- Curing agent [Aromatic amine curing agent] ⁇ 4,4′-diaminodiphenylsulfone (product name: “Seika Cure S”, manufactured by Wakayama Seika Kogyo Co., Ltd.).
- thermoplastic resin insoluble in epoxy resin [B] thermoplastic resin insoluble in epoxy resin [B]
- thermoplastic resin] -Polyamide fine particles obtained by the following production method (average particle size: 13 ⁇ m) 90 parts of transparent polyamide ("Grillamide (registered trademark)” TR55, manufactured by Ms Chemie Japan Co., Ltd.), 7.5 parts of epoxy resin ("jER (registered trademark)” 828, manufactured by Mitsubishi Chemical Corporation) and curing agent 2.5 parts ("Tomide (registered trademark)”# 296, manufactured by T & K Toka) were added to a mixed solvent of 300 parts of chloroform and 100 parts of methanol to obtain a homogeneous solution.
- the obtained uniform solution was sprayed in the form of a mist toward the liquid surface of 3000 parts of n-hexane being stirred using a spray gun for coating to precipitate a solute.
- the precipitated solid was separated by filtration, washed well with n-hexane, and then vacuum-dried at a temperature of 100 ° C. for 24 hours to obtain epoxy-modified polyamide particles having a spherical semi-IPN structure.
- Void ratio measurement of fiber reinforced composite material After stacking 16 prepregs of 300 mm length ⁇ 150 mm width in one direction to form a prepreg laminate, 100 ⁇ m thick PTFE films were placed on both surfaces of the prepreg laminate. It was placed on an aluminum plate having a thickness of 10 mm and covered with a nylon film. Further, under a 25 ° C. environment, the degree of vacuum around the prepreg laminate was set to 3 kPa, and left for 3 hours to remove volatile components. Thereafter, while maintaining the degree of vacuum at 3 kPa, the temperature was raised to 120 ° C. at a rate of 1.5 ° C./min, held for 180 minutes, and further raised to a temperature of 180 ° C.
- the fiber-reinforced composite material was obtained by holding for 120 minutes and curing the resin. Three sample pieces of 10mm length x 10mm width were cut out from this fiber reinforced composite material, and after polishing the cross section, observed with an optical microscope using a 50x lens so that the upper and lower surfaces of the fiber reinforced composite material were within the field of view. And acquired the image. The void ratio of each image was calculated by calculating the ratio of the void area and the total cross-sectional area from the acquired image. The same operation was carried out at three places for each sample, a total of nine places, and the average value was taken as the void ratio at each evaluation level.
- CAI compressive strength after impact
- Example 1 Add 60 parts by weight of "Araldite (registered trademark)” MY721 and 40 parts by weight of “jER (registered trademark)” 825 to the kneader, and then add 12 parts by weight of "Sumika Excel (registered trademark)” PES5003P and heat. Next, 46 parts by mass of “Seika Cure S” as a curing agent was kneaded to prepare an epoxy resin composition (for the first film) containing no thermoplastic resin insoluble in the epoxy resin.
- the prepared two types of epoxy resin compositions were each applied to release paper with a knife coater to prepare two types of resin films of 52 g / m 2 .
- a resin film that does not contain thermoplastic resin particles is a first film
- a resin film that contains a thermoplastic resin is a second film.
- the first film is attached to one side, and the resin is impregnated while pressing a roller having a surface temperature of 100 ° C. It was.
- a second film containing polyamide fine particles was impregnated on the back surface of the carbon fiber sheet while pressing a roller having a surface temperature of 100 ° C. In this way, a unidirectional prepreg having a resin mass fraction of 35% was produced.
- Example 2 Verification of influence of resin impregnation temperature>
- the roller surface temperature when transferring the first film was the same as in Example 1 except that Example 2 was 110 ° C., Example 3 was 120 ° C., Example 4 was 130 ° C., and Example 5 was 140 ° C.
- a prepreg was prepared by the method to obtain a fiber-reinforced composite material.
- Example 6 and 7 Influence of viscosity of epoxy resin>
- a prepreg was produced in the same manner as in Example 1 except that the content of “Sumika Excel (registered trademark)” PES5003P in the first film epoxy resin composition was 20 parts in Example 6 and 30 parts in Example 7. Thus, a fiber reinforced composite material was obtained.
- Example 9 Half of the “jER (registered trademark)” 825 in the epoxy resin composition for the first film and the epoxy resin composition for the second film was replaced with “Epiclon (registered trademark)” 830, and “Sumika Excel (registered) of the second film was registered. (Trademark) Except that the amount of PES5003P is 15 parts by mass, and the roller surface temperature when transferring the first film is 140 ° C., a prepreg is prepared in the same manner as in Example 1 to obtain a fiber-reinforced composite material It was.
- Examples 1 to 5 and Comparative Examples 1 and 2 As shown in Tables 1 and 3, even in a prepreg having the same impregnation rate ⁇ , the particle layer is arranged on one side, and the center of gravity of the unimpregnated part is localized on the particle side, thereby increasing the air flow rate.
- the void ratio of the fiber reinforced composite material was also 1% or less, and the CAI value was also high. It is thought that the improvement in the removal efficiency of the volatile matter in the non-impregnated region led to a decrease in the amount of void generation and an improvement in the CAI value.
- Examples 6 to 7 and Comparative Example 3 As shown in Tables 2 and 3, in Examples 6 to 7, the thermoplastic resin component was added in a larger amount than Examples 1 to 5. As a result, although the resin viscosity increases and the impregnation rate ⁇ decreases, the handling property of the prepreg is somewhat deteriorated, but the impregnation rate ⁇ is in the range of 30% to 95%, thereby increasing the air flow rate. The void ratio was 1% or less, and the CAI value was also increased. In Comparative Example 3, it was difficult to produce a prepreg laminate, but it is considered that the degree of impregnation was too low.
- Examples 8 to 9 and Comparative Examples 4 and 5 As shown in Tables 2 and 3, in Examples 8 to 9, the impregnation ratio ⁇ with respect to Example 1 is increased by setting the roller temperature higher. Compared with Comparative Example 4, the localization parameter ⁇ is the same, but the impregnation rate ⁇ is 30 to 95%, and the prepreg in-plane penetration coefficient K is 20 ((1- ⁇ )) / 100) It has been clarified that a low void ratio and a high CAI are exhibited by setting the value to 4.0 ⁇ 10 ⁇ 12 m 2 or more. Although many voids were generated in Comparative Example 5, it is considered that the localization parameter ⁇ is too high and the continuity of the unimpregnated portion cannot be ensured.
- Epoxy resin composition 2 Thermoplastic resin insoluble in epoxy resin 3: Interlayer forming layer 4: Epoxy resin layer 5: Reinforcing fiber 6: Reinforcing fiber layer 7: Unimpregnated layer 8: Equal line 9: Prepreg laminate 10: Sealant 11: Cover film 12: Metal plate 13: Glass tape 14: Air flow meter 15: Vent 16: Pressure gauge 17: Vacuum pump
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Abstract
Description
また、これらのエポキシ樹脂と硬化剤からなるエポキシ樹脂組成物(硬化助剤を含んでいても良い)の粘度が低く、プリプレグのハンドリング性に問題が生じる場合は、エポキシ樹脂組成物を予備反応させ、粘度を増加させることも有効である。粘度の増加に伴い、プリプレグに適切な粘着性を付与することができ、ハンドリング性が向上したり、あるいはプリプレグの保存安定性を向上させることが可能となる。
σ=(H5-H2)/T
と定義する。
(1)構成要素[A]:強化繊維
[炭素繊維]
・炭素繊維(製品名:“トレカ(登録商標)”T800S-24K-10E、フィラメント数24,000、引張強度5.9GPa、引張弾性率290GPa、引張伸度2.0%、東レ株式会社製)。
[エポキシ樹脂]
・ビスフェノールA型エポキシ樹脂(製品名:“jER(登録商標)”825、三菱ケミカル(株)製)
・テトラグリシジルジアミノジフェニルメタン(製品名:“アラルダイト(登録商標)”MY721、ハンツマン・アドバンスト・マテリアルズ社製)
・ビスフェノールF型エポキシ(製品名:“エピクロン(登録商標)”830、DIC(株)製)。
[芳香族アミン硬化剤]
・4,4’-ジアミノジフェニルスルホン(製品名:“セイカキュアS”、和歌山精化工業(株)製)。
[熱可塑性樹脂]
・下記の製造方法で得られたポリアミド微粒子(平均粒子径:13μm)
透明ポリアミド(“グリルアミド(登録商標)”TR55、エムスケミー・ジャパン(株)製)90部、エポキシ樹脂(“jER(登録商標)”828、三菱ケミカル(株)社製)7.5部および硬化剤(“トーマイド(登録商標)”#296、(株)ティーアンドケイ東華製)2.5部を、クロロホルム300部とメタノール100部の混合溶媒中に添加して均一溶液を得た。次に、得られた均一溶液を塗装用のスプレーガンを用い、撹拌している3000部のn-ヘキサンの液面に向かって霧状に吹き付けて溶質を析出させた。析出した固体を濾別し、n-ヘキサンでよく洗浄した後に、100℃の温度で24時間の真空乾燥を行い、球状のセミIPN構造を有するエポキシ改質ポリアミド粒子を得た。
・ポリエーテルスルホン(製品名:“スミカエクセル(登録商標)”PES5003P、住友化学(株)社製)。
以下の測定方法を用いて各実施例のエポキシ樹脂組成物およびプリプレグを測定した。
プリプレグをナイフにより切断し、その破面をSEM(“VHX(商標登録)”5000”キーエンス社製)により観察し、前記手法に従い、含浸率φ=(エポキシ樹脂組成物が付着していない炭素繊維の本数)/(単位幅あたりに存在する炭素繊維の総本数)とした。
プリプレグをナイフにより切断し、その破面をSEM(“VHX(商標登録)”5000、キーエンス社製)により観察し、各炭素繊維の中心点の座標を取得し、前記手法に従い、局在化パラメータσを算出した。
前記手法に従い、繊維配向方向100mm、繊維垂直方向50mmの短冊状プリプレグを8層積層し、プリプレグ積層体の繊維方向に流れる空気量、プリプレグ両端の気圧Pa、Pvを測定した。また、式1に従い、面内方向の浸透係数Kを評価した。
23℃の環境下でプリプレグをナイフで切断した際に、その端部に発生する毛羽、積層時のプリプレグの面外方向の剥離、積層時の貼り合わせによる修正のしやすさを確認し、以下の基準によりその優劣を判断した。
A :良好
B :積層可能であるが、端部から一部の毛羽が発生
C :積層可能であるが、端部から毛羽が発生し、貼り合わせの修正も工夫を要する
D :不良。
縦300mm×横150mmのプリプレグを一方向に16枚積層し、プリプレグ積層体とした後、プリプレグ積層体の両表面に厚さ100μmのPTFEフィルムを配置し、厚さ10mmのアルミ板の上にのせ、ナイロンフィルムで覆った。さらに、25℃環境下で、プリプレグ積層体の周囲の真空度を3kPaとし、3時間放置し、揮発分を除去した。その後、真空度を3kPaに維持したまま1.5℃/分の速度で120℃の温度まで昇温して180分間保持し、さらに1.5℃/分の速度で180℃の温度まで昇温して120分間保持し、樹脂を硬化させることにより、繊維強化複合材料を得た。この繊維強化複合材料から縦10mm×横10mmのサンプル片を3個切り出し、その断面を研磨後、繊維強化複合材料の上下面が視野内に収まるように50倍のレンズを用いて光学顕微鏡で観察し、画像を取得した。取得画像から、ボイド領域と総断面積の割合を算出することにより各画像のボイド率を算出した。同様の作業を各サンプルにつき3箇所、合計9箇所実施し、その平均値を各評価水準のボイド率とした。
一方向プリプレグを、45度ずつずらしながら24枚積層することで、[+45°/0°/-45°/90°]3sの積層構成を有するプリプレグ積層体とし、プリプレグ積層体の両表面に厚さ100μmのPTFEフィルムを配置し、厚さ10mmのアルミ板の上にのせ、ナイロンフィルムで覆った。さらに、25℃環境下で、プリプレグ積層体の周囲の真空度を3kPaとし、3時間放置し、揮発分を除去した。その後、1.5℃/分の速度で120℃の温度まで昇温し、真空度を3kPaに維持したまま180分間保持し、その後1.5℃/分の速度で180℃の温度まで昇温し、120分間保持してプリプレグを硬化させ、繊維強化複合材料を作製した。この繊維強化複合材料から、縦150mm×横100mmのサンプルを切り出し、SACMA SRM 2R-94に従ってサンプルの中心部に6.7J/mmの落錘衝撃を与え、衝撃後圧縮強度を求めた。
60質量部の“アラルダイト(登録商標)”MY721および40質量部の“jER(登録商標)”825を混練機中に加え、さらに12質量部の“スミカエクセル(登録商標)”PES5003Pを加えて加熱溶解させ、次いで硬化剤として“セイカキュアS”を46質量部混練して、エポキシ樹脂に不溶な熱可塑樹脂を含まないエポキシ樹脂組成物(第1フィルム用)を作製した。同様に、60質量部の“アラルダイト(登録商標)”MY721および40質量部の“jER(登録商標)”825を混練機中に加え、さらに12質量部の“スミカエクセル(登録商標)”PES5003Pを加えて加熱溶解させ、熱可塑性樹脂粒子であるポリアミド微粒子を45質量部混練し、次いで硬化剤として“セイカキュアS”を46質量部混練して、エポキシ樹脂に不溶な熱可塑樹脂を含むエポキシ樹脂組成物(第2フィルム用)を作製した。
第1フィルムを転写する際のローラー表面温度を、実施例2は110℃、実施例3は120℃、実施例4は130℃、実施例5は140℃にした以外は実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂組成物の“スミカエクセル(登録商標)”PES5003Pの含有量を実施例6は20部、実施例7は30部とする以外は実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂組成物および第2フィルム用エポキシ樹脂組成物の“jER(登録商標)”825の半量を“エピクロン(登録商標)”830に置き換え、第2フィルムの“スミカエクセル(登録商標)”PES5003Pの量を18質量部とし、第1フィルムを転写する際のローラー表面温度を130℃とする以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂組成物および第2フィルム用のエポキシ樹脂組成物の“jER(登録商標)”825の半量を“エピクロン(登録商標)”830に置き換え、第2フィルムの“スミカエクセル(登録商標)”PES5003Pの量を15質量部とし、第1フィルムを転写する際のローラー表面温度を140℃とする以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂と第2フィルム用エポキシ樹脂の両方にポリアミド微粒子を23部添加する点、および、ローラー表面温度を比較例1は140℃、比較例2は120℃に変えた点以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂組成物および第2フィルム用のエポキシ樹脂組成物の“jER(登録商標)”825の半量を“エピクロン(登録商標)”830に置き換え、第2フィルムのスミカエクセル(登録商標)”PES5003Pの量を18質量部とし、第1フィルム、第2フィルムを転写する際のローラー表面温度を70℃に変えた以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
第1フィルム用エポキシ樹脂組成物および第2フィルム用のエポキシ樹脂組成物のスミカエクセル(登録商標)”PES5003Pの含有量を8質量部、第1フィルムを転写する際のローラー表面温度を130℃、第2フィルムを転写する際のローラー表面温度を120℃とする以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
<比較例5>
第1フィルム用エポキシ樹脂組成物および第2フィルム用のエポキシ樹脂組成物のスミカエクセル(登録商標)”PES5003Pの含有量を6質量部、第1フィルムを転写する際のローラー表面温度を140℃、第2フィルムを転写する際のローラー表面温度を100℃とする以外は、実施例1と同様の方法でプリプレグを作製し、繊維強化複合材料を得た。
表1、表3に示されるように、含浸率φが同等のプリプレグにおいても、粒子層を片側に配置し、未含浸部の重心位置を粒子側に局在化させることにより、通気量が高く、繊維強化複合材料のボイド率も1%以下となり、CAI値も高くなった。未含浸領域の揮発分の除去効率が向上することにより、ボイド発生量の低下、およびCAI値の向上につながったと考えられる。
表2、表3に示すように、実施例6~7では熱可塑性樹脂成分の配合量を実施例1~5対比多く配合した。その結果、樹脂が増粘し含浸率φが低下することにより、プリプレグのハンドリング性はやや悪化するものの、含浸率φを30%~95%の範囲にすることで、通気量を高くすることができ、ボイド率を1%以下とし、CAI値も高くなった。比較例3では、プリプレグ積層体の作製が困難であったが、含浸度が低すぎることが原因と考えられる。
表2、表3に示すように、実施例8~9では、ローラー温度を高めに設定することで、実施例1対比含浸率φを高めている。比較例4と比較して、いずれも局在化パラメータσは同等だが、含浸率φを30~95%、およびプリプレグの面内方向の浸透係数Kを20((1-φ))/100)×4.0×10-12 m2以上にすることにより、低ボイド率、高CAIを示すことが明らかとなった。比較例5はボイドが多数発生したが、局在化パラメータσが高すぎるため、未含浸部の連続性が確保出来ないことが原因と考えられる。
2:エポキシ樹脂に不溶な熱可塑性樹脂
3:層間形成層
4:エポキシ樹脂層
5:強化繊維
6:強化繊維層
7:未含浸層
8:等分線
9:プリプレグ積層体
10:シーラント
11:カバーフィルム
12:金属板
13:ガラステープ
14:空気流量計
15:通気口
16:圧力計
17:真空ポンプ
Claims (5)
- 層状に配置された強化繊維[A]に、エポキシ樹脂[B]および硬化剤[C]を含むエポキシ樹脂組成物が部分的に含浸され、その含浸率φが30~95%であって、該エポキシ樹脂[B]に不溶な熱可塑性樹脂[D]がプリプレグ片側表面に偏在しており、かつ該強化繊維[A]の層において、エポキシ樹脂組成物の未含浸部が該熱可塑性樹脂[D]が偏在する側に局在化しており、かつ該局在化の度合いを規定する局在化パラメータσが、0.10<σ<0.45の範囲にあるプリプレグ。
- 面内方向の浸透係数Kが2.0×(1-φ/100)×10-14[m2]以上である、請求項1に記載のプリプレグ。
- 強化繊維[A]が一方向に配列した連続繊維である、請求項1または2に記載のプリプレグ。
- 強化繊維[A]が織物形態である、請求項1または2に記載のプリプレグ。
- 請求項1~4のいずれかに記載のプリプレグを硬化してなる繊維強化複合材料。
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CN110461917B (zh) | 2022-04-12 |
CN110461917A (zh) | 2019-11-15 |
US20200010632A1 (en) | 2020-01-09 |
US11136442B2 (en) | 2021-10-05 |
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