WO2019078242A1 - Article moulé en plastique renforcé par des fibres - Google Patents

Article moulé en plastique renforcé par des fibres Download PDF

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Publication number
WO2019078242A1
WO2019078242A1 PCT/JP2018/038644 JP2018038644W WO2019078242A1 WO 2019078242 A1 WO2019078242 A1 WO 2019078242A1 JP 2018038644 W JP2018038644 W JP 2018038644W WO 2019078242 A1 WO2019078242 A1 WO 2019078242A1
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WO
WIPO (PCT)
Prior art keywords
reinforced plastic
fiber
rib
plate
ribs
Prior art date
Application number
PCT/JP2018/038644
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English (en)
Japanese (ja)
Inventor
藤田雄三
足立健太郎
唐木琢也
Original Assignee
東レ株式会社
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Publication date
Application filed by 東レ株式会社 filed Critical 東レ株式会社
Priority to CN201880064149.2A priority Critical patent/CN111183018A/zh
Priority to JP2018563192A priority patent/JPWO2019078242A1/ja
Publication of WO2019078242A1 publication Critical patent/WO2019078242A1/fr

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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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • 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
    • B29C70/06—Fibrous reinforcements only
    • 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
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • 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

Definitions

  • the present invention relates to a fiber-reinforced plastic molded article in which a rib which is a projecting portion is provided on the surface of a thin plate-like portion.
  • Fiber-reinforced plastic consisting of reinforcing fiber and resin attracts attention also in industrial applications because it has high specific strength, high specific rigidity, excellent mechanical properties, and high functional properties such as weather resistance and chemical resistance. It has been developed for structural applications such as spacecraft, automobiles, railways, ships, electric appliances, sports etc., and its demand is increasing year by year.
  • the molding material which consists of a discontinuous reinforcement fiber and a thermoplastic resin is arrange
  • a molded article having a rib is obtained from two or more kinds of molding materials, and the effect of suppressing warpage is found by molding a fiber-reinforced plastic molded article so that a plurality of ribs intersect.
  • the molded article which has a rib is obtained by pressing the incised prepreg which consists of the reinforced fiber and resin which were orientated to one direction, and made the reinforced fiber discontinuous by incising. By maintaining the layered structure when laminating the incised prepreg, it is possible to form a rib having high mechanical properties.
  • an object of the present invention is to provide a fiber-reinforced plastic molded article which exhibits sufficient mechanical properties while being extremely thin.
  • the present inventors provide the following fiber reinforced plastic molded articles in order to solve this subject. That is, it is a fiber reinforced plastic molded article including a fiber reinforced plastic structure, wherein the fiber reinforced plastic structure includes a fiber and a resin, and has a plate-like portion and a rib protruding from the surface of the plate-like portion.
  • the plate-like portion has a volume content of fibers of 50 to 70% and an average thickness of 1.5 mm or less, and the ribs have an average width of 0.1 to 1.5 mm.
  • a rib on a plate-like portion which is a thin fiber reinforced plastic it is possible to provide a fiber reinforced plastic molded article having a light weight and high mechanical properties.
  • the fiber reinforced plastic molded article may be simply referred to as a molded article, and the reinforcing fibers contained in the fiber reinforced plastic molded article may be simply referred to as a fiber.
  • the fiber reinforced plastic molded article of the present invention includes a fiber reinforced plastic structure including fibers and a resin, and the fiber reinforced plastic structure includes a plate and a rib protruding from the plate.
  • a fiber-reinforced plastic molded article is a joined body with a part or member which is not fiber-reinforced plastic such as metal if it contains a fiber-reinforced plastic structure, or a joined body with a fiber-reinforced plastic part not containing ribs. On the other hand, it may be formed only by the fiber reinforced plastic structural part.
  • the plate-like portion of the fiber-reinforced plastic structure refers to a fiber-reinforced plastic of a plate-like body, and a rib provided on this is the main part of the fiber-reinforced plastic structure according to the present invention.
  • the plate-like portion of the fiber reinforced plastic structural portion may be simply referred to as a plate-like portion.
  • the volume content of fibers (hereinafter referred to as Vf) is 50 to 70%.
  • Vf volume content of fibers
  • the preferred range of Vf is 53 to 63%. More preferably, it is 55% to 60%.
  • the range of Vf may be a range combining any of the above upper limit and the lower limit.
  • the average thickness of the plate-like portion is 1.5 mm or less.
  • the average thickness of the plate-like portion is large, mechanical properties are improved but weight is increased.
  • the thickness of the base material before molding is larger, more base material flows into the rib, so that the moldability of the rib is improved. Therefore, in the fiber-reinforced plastic structure after molding, when the thickness of the plate-like portion is larger than 1.5 mm, although it is possible to easily provide many ribs, the weight as the entire molded product is compared Grow big.
  • the fiber-reinforced plastic molded article of the present invention even if the thickness of the plate-like portion of the fiber-reinforced plastic structure is 1.5 mm or less, the average width of the rib and the state of fibers existing over the plate-like portion and the rib It has been found that by setting the content in a specific range, it is possible to obtain a molded article having a well-balanced rib structure and a moldable rib, and having high rigidity and maintaining the lightness. It is not easy to realize the mechanical properties required for the above-mentioned structural applications by using the plate-like part of the fiber reinforced plastic structural part having a thickness of 1.5 mm or less, but in the present invention, ribs are used.
  • the mechanical properties can be sufficiently maintained even at an average thickness of 1.5 mm or less due to the structure of the above and the high fiber volume content.
  • the average thickness of the plate-like portion of the fiber-reinforced plastic structure is preferably 0.9 mm or less.
  • the average thickness of the plate-like part of the fiber reinforced plastic structural part is too thin, it can not be said that the plate-like part itself may not be broken, so the average thickness of the plate-like part is 0.2 mm or more preferable.
  • the average thickness of the plate-like portion is more preferably 0.25 to 0.75 mm, still more preferably 0.35 to 0.55 mm.
  • the average thickness of the plate-like portion may be a range combining any of the above upper limit and the lower limit.
  • the plate-like portion may include a portion having a thickness of 1.5 mm or more as long as the average thickness is 1.5 mm or less.
  • the method of measuring the average thickness of the plate-like portion is as described later in the Examples.
  • the plate-like portion may have a laminated structure or may not have a laminated structure.
  • the fibers may be oriented only in one direction with respect to the orientation direction of the fibers, but in that case, the fibers tend to be broken in the non-fiber direction, so a laminate configuration having a cross ply or a quasi-isotropic laminate configuration It is preferable to have.
  • the number of stacked layers depends on the thickness of each layer, but it is preferable that four or more layers be included because the rigidity of the plate-like portion can be increased in multiple directions.
  • the maximum number of realistic stacks is 20. When Vf is 50 to 70%, a sufficient amount of reinforcing fibers can be contained in each layer even if the thickness of each layer is thin in the laminated structure, and the degree of freedom in the lamination design is improved.
  • the average width of the individual ribs is 0.1 to 1.5 mm.
  • “the width of the rib” is not the longitudinal direction of the rib but the length in the lateral direction (the thickness when the rib is viewed as a face plate), and it is measured in the direction in which the measured value becomes minimum at the measurement point. It is a value.
  • the average width of the rib is arbitrarily selected at three locations from 10 to 30%, 30 to 70%, and 70 to 90% from the end of the rib in the longitudinal direction of the rib (hereinafter referred to , And may be abbreviated as the measurement position in the longitudinal direction of the rib), from the range of 30 to 70% in the height direction of the rib (hereinafter sometimes referred to as the measurement position in the height direction of the rib)
  • the measurement position can be selected one by one and obtained by averaging the measured width values.
  • the height direction of the rib refers to a direction perpendicular to the surface of the plate-like portion.
  • the rib width has a shape that changes in the height direction of the rib
  • 10 measurement points shall be taken at equal intervals throughout the longitudinal direction of the rib, and the values of the width of 10 points shall be averaged. .
  • the larger the average width of the ribs the higher the reinforcing effect.
  • the average width of the ribs is too large, the weight of the molded article increases, so 1.5 mm or less is preferable. If the average width of the ribs is too small, the ribs may be broken, so 0.1 mm or more is preferable.
  • the average width of the more preferable ribs is 0.3 to 1.2 mm, more preferably 0.5 to 1.0 mm.
  • the rib may include an area having a width outside the range of 0.1 to 1.5 mm in the rib if the average width is 0.1 to 1.5 mm.
  • the average width of the rib may be a range combining any of the above upper limit and the lower limit.
  • the width of the rib becomes gradually thinner from the root of the rib to the tip of the rib, it is preferable because the release from the press die becomes easy at the time of production of the fiber reinforced plastic molded product.
  • the volume content (Vf) of fibers in the ribs is not particularly limited, but preferably more than 30% in order to maintain the mechanical properties.
  • the Vf in the rib is more preferably 50 to 70% as in the plate-like portion.
  • the method of measuring Vf is as described later in the Examples.
  • the rib of the fiber reinforced plastic structure portion includes fibers which exist over both the rib and the plate-like portion and in which the height in the height direction of the rib reaches 0.5 mm or more.
  • the bonding strength is a concept representing the resistance to breakage between the rib and the plate-like portion.
  • the ribs are integrally formed and project from the plate-like portion and are not joined, but resistance to breakage between the rib and the plate-like portion is the rib and plate-like shape. Since it is a characteristic corresponding to the joint strength in the joined part, it is expressed as joint strength for convenience. The higher the height of the fibers in the rib, the harder it is to break. It is preferable that fibers which are continuous with the plate-like portion and reach 1.0 mm or more in the rib are included. More preferably, it is 1.5 mm or more.
  • the fiber which exists over both a plate-like part and a rib is contained 5 mm or more in a plate-like part. More preferably, it is 8 mm or more. With the fibers present over both the plate and the rib, the practical maximum value of the length that can be included in the plate is 50 mm.
  • the fibers present across both the plate and the rib can be confirmed from the cross section of the rib.
  • the cross section including the plate-like part is extracted one by one and observed with a microscope.
  • the plate-like portion has a layer structure
  • fibers which are continuous from the plate-like portion and have a height of 0.5 mm or more when at least one layer reaches 0.5 mm or more in the height direction of the rib May be considered as including.
  • FIG. 1 shows an example of a fiber-reinforced plastic structure according to the invention having a plate 1 and a rib 2, wherein the rib contains fibers 3 present over both the plate and the rib. ing.
  • the height L reached by the fibers 3 in the ribs is equal to the average thickness of the plates from the distance between the rib-free surface 4 of the plates and the maximum height in the ribs of the fibers 3. It can be calculated by
  • the ribs may contain fibers that do not exist over both the plate-like portion and the ribs but exist only in the ribs. Such fibers have the effect of improving the longitudinal rigidity of the ribs.
  • the ribs may have a laminated structure or may not have a laminated structure. The narrower the rib, the more difficult it is to form the rib with a stacked configuration.
  • at least the fiber reinforced plastic structure at the root of the rib has a laminated structure in order to include fibers that span both the plate and the rib.
  • the fiber-reinforced plastic structure at the root of the rib means, in the fiber-reinforced plastic structure, the surface 4 of the plate-like part on the side where the rib is not formed in the plate-like part directly below the rib is a reference plane It refers to the area between the reference surface and the surface side where the ribs are formed from the reference surface and the position separated by the average thickness of the upper portion of the plate measured by the method described in the later-described embodiment.
  • the height of the rib is not particularly limited, and the higher the height, the higher the effect of improving the rigidity, but if the height is too high, the rib itself is easily broken.
  • the maximum height of a realistic rib depends on the size of the plate-like portion, but is preferably 50 mm or less.
  • the height of the rib refers to the distance in the height direction of the rib from the surface on the side having the rib of the plate-like portion to the tip of the rib.
  • the shape of the plate-like portion has a curved surface or an uneven surface, or when the rib shape is complicated, it may take different values depending on the position where the height of the rib is measured.
  • the rib longitudinal direction Ten measurement points shall be taken at equal intervals throughout the above, and the maximum value of the heights of the ten ribs shall be the height of the ribs.
  • the fiber reinforced plastic molded article is provided with a plurality of ribs, the heights of the ribs are measured for all the ribs, and the maximum value of those values is taken as the height of the rib of the fiber reinforced plastic molded article.
  • fibers mean fibers generally used as reinforcing fibers of fiber reinforced plastics, such as glass fibers, Kevlar fibers, carbon fibers, graphite fibers or boron fibers.
  • fibers are preferable from the viewpoint of specific strength and specific elastic modulus. Multiple types of fibers may be mixed.
  • the resin contained in the fiber-reinforced plastic structure may be a thermosetting resin or a thermoplastic resin.
  • a thermosetting resin unsaturated polyester resin, vinyl ester resin, an epoxy resin, benzoxazine resin, a phenol resin, a urea resin, a melamine resin, a polyimide resin, etc. are mentioned. Variations of these resins and resins of two or more blends can also be used. Further, these thermosetting resins may be resins which are self-cured by heat, or may contain a curing agent, a curing accelerator and the like.
  • thermoplastic resin for example, polyamide (PA), polyacetal, polyacrylate, polysulfone, ABS, polyester, acrylic, polybutylene terephthalate (PBT), polycarbonate (PC), polyethylene terephthalate (PET), polyethylene, polypropylene, Polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyether imide (PEI), polyether ketone ketone (PEKK), liquid crystal polymer, fluorocarbon resin such as vinyl chloride and polytetrafluoroethylene, silicone, etc. may be mentioned .
  • PA polyamide
  • PBT polybutylene terephthalate
  • PC polycarbonate
  • PET polyethylene terephthalate
  • PET polyethylene
  • PPS polypropylene
  • PPS polyphenylene sulfide
  • PEEK polyether ether ketone
  • PEI polyether imide
  • PEKK polyether ketone ketone
  • liquid crystal polymer fluorocarbon resin such as vinyl
  • thermosetting resin is preferable, and an epoxy resin composition is particularly preferable.
  • the thermosetting resin may be blended with a thermoplastic resin.
  • the number of ribs is not limited to one as shown in FIG. 2 (a), and a plurality of ribs are preferably present as shown in FIGS. 2 (b) to 2 (e).
  • the number of ribs is not particularly limited.
  • the plurality of ribs may have different widths, different lengths, different heights, or they may be ribs of the same shape.
  • FIG. 2E shows an example where two ribs intersect.
  • ribs As a preferred embodiment in the case where a plurality of ribs are present, an embodiment in which three or more ribs are present and at least three of them do not cross each other can be mentioned.
  • the relatively wide range of the plate-like portion can be reinforced with the ribs.
  • an embodiment including a portion having a distance of 15 mm or less is preferable, and more preferably a portion having 13 mm or less It is an aspect. More preferably, the distance between any ribs is 15 mm or less at any point. In this aspect, it is particularly preferable if the ribs are substantially parallel.
  • the presence of a plurality of ribs can reinforce the wide range of the plate-like portion, but by setting the distance between the ribs to 15 mm or less, the portions of the plate-like portion not directly below the ribs can be reinforced. The reinforcing effect can be exerted, and the plate-like portion can be reinforced more firmly.
  • the distance between any ribs is 13 mm or less.
  • the minimum distance between realistic ribs is 3 mm.
  • the three or more ribs are provided at places where reinforcement of the plate-like part is necessary, thereby reinforcing the plate-like part.
  • the area surrounded by the three or more ribs preferably has an area of 60% or more of the area of the plate-like portion.
  • the area surrounded by three or more ribs means the side of two of the three or more ribs that are the farthest apart and the side consisting of line segments connecting the longitudinal ends of adjacent ribs. Area of the area enclosed by
  • Another preferred embodiment in the case where a plurality of ribs are present includes an embodiment in which at least two ribs cross each other. More preferably, it is an aspect in which four or more ribs exist, and three or more ribs that do not intersect with each other and ribs that intersect with those ribs coexist. By having the intersecting ribs, the rigidity can be improved in a plurality of directions.
  • the plate-like portion may have a curved shape.
  • the rib may have a height variation in the longitudinal direction.
  • the plate-like portion has a dome shape, it may have a crescent shape extending in the longitudinal direction when the rib is viewed from the side direction.
  • a metal may be laminated on the surface of the plate-like portion of the fiber-reinforced plastic structure, which does not have a rib. Reinforcing with fiber-reinforced plastic can obtain lighter molded products in spite of the same rigidity, even if it is intended to obtain molded products with sufficient rigidity using metal alone, including ribs If it is a fiber reinforced plastic structure part, equivalent rigidity can be obtained while further reducing the weight of the fiber reinforced plastic molded article.
  • the metal and the fiber reinforced plastic structure may be bonded using an adhesive or may be bonded by a resin of a plate-like part.
  • the material of the metal is not particularly limited, pure metals such as aluminum, iron, copper, titanium, molybdenum, chromium, magnesium, nickel, zinc, lead, tin and the like can be mentioned.
  • titanium, stainless steel, duralumin or a titanium alloy is preferably used in terms of excellent lightness, strength and impact resistance.
  • carbon may be blended as appropriate, or part of the surface or components may be oxidized.
  • the thickness of the metal is not particularly limited, but if it is too thick, the fiber-reinforced plastic molded article becomes heavy, so it is preferable to be smaller than 3 mm. On the other hand, since it will be easily scraped off by abrasion etc. when too thin, it is preferable that it is 0.5 mm or more.
  • a plurality of incisions are inserted into a continuous fiber prepreg composed of fibers and resin oriented in one direction to make the fibers discontinuous (average length is 10 to 50 mm). It can obtain by press-forming the incised prepreg laminated body which laminated
  • the average length of discontinuous fibers in the incised prepreg is preferably 10 to 50 mm. The more preferable average length of discontinuous fibers is 10 to 30 mm.
  • discontinuous fibers in the incised prepreg flow at the time of molding to obtain a fiber-reinforced plastic structure having a large volume content (Vf) of fibers while having ribs. it can.
  • the Vf of the obtained fiber reinforced plastic structural part can also be 50 to 70%.
  • the thickness of the incised prepreg is preferably 0.05 mm to 1.5 mm. When it is too thin, the number of laminations at the time of molding increases, and it takes time. If it is too thick, the degree of freedom in selecting the laminated structure is reduced.
  • the absolute value of the angle between the incised portion and the fiber is preferably 2 to 60 °.
  • the absolute value of the angle between the incision and the fiber is more preferably 2 to 45 ° from the viewpoint of achieving both the flowability and the mechanical properties of the substrate.
  • the absolute value of the angle between the incision and the fiber is 25 ° or less, the mechanical characteristics are significantly improved, and from this point of view, the absolute value of the angle between the incision and the fiber is 2 to 25 °. Is more preferred.
  • the laminated structure of the incised prepreg is preferably a symmetrical laminated structure in order to suppress thermal deformation during molding.
  • it is not necessary to be symmetrical lamination, and heat shrinkage of metal and heat shrinkage of FRP are equal, especially when heating simultaneously to cure and bond simultaneously with metal. It is preferable to adjust the lamination configuration so that
  • the surface without the rib of the plate-like part does not necessarily need to use the incised prepreg, and may be a continuous fiber prepreg in which there is no incised.
  • the incised prepreg on the surface layer the orientation direction of the fibers oriented in one direction included in the incised prepreg (hereinafter referred to as the incised prepreg on the surface layer) in contact with the rib mold is at an acute angle side with respect to the longitudinal direction in the rib mold recess.
  • the absolute value is ⁇ s, it is preferable that ⁇ s be smaller than 60 °.
  • the fibers can easily flow into the rib-shaped recess, and the high ribs filled with the fibers in the resin can be made to project.
  • the angle is more preferably 45 ° or less.
  • fibers in each recess are made by setting the orientation direction of the fibers oriented in one direction contained in the longitudinal direction of each recess and in the cut prepreg of surface layer smaller than 60 °. Is more likely to flow. In particular, the effect is remarkable when the rib mold has a narrow recess.
  • the present embodiment can be preferably applied to the case where the width in the direction perpendicular to the longitudinal direction of the recess is 0.1 to 1.5 mm.
  • the mechanical properties of the plate-like portion may be lowered.
  • the thinner the rib to be projected the more the rib can be projected while maintaining the mechanical characteristics of the plate-like portion.
  • the surface area is larger and the heat radiation effect can also be expected by arranging a plurality of narrow ribs rather than arranging one wide rib as a structure.
  • the incised prepreg with ⁇ of 45 ° or less Is preferably contained in the same number or more as the number of incised prepregs in which ⁇ is greater than 45 °, and an embodiment containing more is preferable.
  • the incised prepreg of the surface layer in the incised prepreg laminate, that is, in the press molding, ⁇ of the incised prepreg disposed at a position closest to the rib type is smaller than 60 ° and a plurality of sheets
  • a prepreg in which ⁇ is 45 ° or less is included in the same number or more as that of the prepreg in which ⁇ is greater than 45 °, and more preferably is included.
  • the rib By making the direction of the fibers not only in the surface incised prepreg but also in the inward inward prepreg at an angle close to the longitudinal direction in the recess, the rib can be easily protruded from the plate-like portion, thereby improving the mechanical characteristics of the rib Do.
  • at least one in-cut prepreg in the in-cut prepreg laminate has a ⁇ of greater than 45 °.
  • a cut prepreg having a ⁇ of 60 ° or more when at least one layer in the substrate laminate is a cut prepreg having a ⁇ of 60 ° or more, a cut prepreg having a ⁇ of 30 ° or less is a cut prepreg having a ⁇ of greater than 60 ° It is an aspect in which the same number or more are included. Also in this embodiment, as in the above, the invention can be preferably applied to the case where the width in the direction perpendicular to the longitudinal direction of the recess is 0.1 to 1.5 mm.
  • the product of the elastic modulus (GPa) of the metal plate and the thickness (mm) is preferably 50 to 300.
  • this product is less than 50, when the incised prepreg laminate is pressurized to project the ribs, a mark of sink marks may be left due to the ribs being projected.
  • the sink marks on the metal surface are presumed to be caused by applying a compressive load to the metal when the fibers around the rib flow into the rib, and the thicker the metal, the higher the elastic modulus, the It becomes difficult to leave marks of sink marks by projecting the ribs, and the appearance of the metal surface is improved.
  • the product of the modulus of elasticity (GPa) and the thickness (mm) of the metal plate is 60 to 250.
  • the product of the elastic modulus (GPa) and the thickness (mm) of the metal plate may be a range in which any of the above upper limit and lower limit is combined.
  • an epoxy resin (“Epicoat (registered trademark)” manufactured by Japan Epoxy Resins Co., Ltd .: 828: 40 parts by mass, “Epicoat (registered trademark)” manufactured by Japan Epoxy Resins Co., Ltd.) 1007 FS: 25 parts by mass, manufactured by DIC Corporation "EPICLON (registered trademark) N 740: 35 parts by mass) and thermoplastic resin polyvinyl formal (" Binilek (registered trademark) "K: 3 parts by weight made by Chisso Corporation) are charged into a beaker, The temperature was raised to 30 minutes and heat kneading was performed for 30 minutes.
  • the obtained epoxy resin composition was applied onto a silicone-coated release paper with a thickness of 100 ⁇ m using a reverse roll coater to prepare a 20 g / m 2 resin film.
  • resin films are overlaid from both sides of a sheet of carbon fiber (Toray Industries, Inc. “TORAYCA (registered trademark)” T700S-12K-50C) aligned in one direction, and heated and pressed to form a resin composition. Impregnation was carried out to prepare a prepreg in which carbon fibers were oriented in one direction and having a carbon fiber basis weight of 100 g / m 2 , a carbon fiber weight fraction of 67%, and a carbon fiber volume content Vf of 57.5%.
  • TORAYCA registered trademark
  • ⁇ Production of incised prepreg> By pressing a rotary blade having a plurality of blades arranged at predetermined positions, a cut penetrating the prepreg was inserted into the prepreg.
  • the rotary blades are arranged alternately with a blade with an angle of + 14 ° and a blade with an angle of -14 °, and the blades are arranged so that all fibers of the prepreg are cut into 15 mm. The ones used were used.
  • the incised prepreg is cut into a size of 100 mm ⁇ 100 mm, and the inlaid prepreg laminate laminated in the configuration described in each example is an upper mold having a recess for forming a rib and a lower mold having no recess. It press-molded using.
  • Examples 3-6, 10-12, and Comparative Examples 4 and 6 are each an example in which a plurality of ribs are formed, in these examples, a plurality of grooves for forming the ribs and wall surfaces forming the grooves are Upper molds provided so as to be parallel to each other were used.
  • the fiber reinforced plastic of the shape shown to FIG. 2 or FIG. 3 was obtained, and made line A horizontal direction and made line B longitudinal direction.
  • the upper and lower molds are preheated to 150 ° C., and the laminated base material is held between the upper and lower molds and held there for 20 seconds, after which a pressure of 6 MPa is applied to the plate-like part Pressure was applied. It hold
  • a fiber-reinforced plastic structure comprising a plate-like portion of 100 mm ⁇ 100 mm and a rib filled with carbon fiber in a resin. It was assumed that the resin flowed out at the time of molding, and Vf was higher than that of the manufactured prepreg.
  • the fiber reinforced plastic structure is a fiber reinforced plastic molded article.
  • the one in which metal is adhered to the fiber reinforced plastic structure portion becomes a fiber reinforced plastic molded article.
  • Vf of the plate-like part was obtained by separating the fibers and the resin by binarization by image processing, and was determined as the area ratio of the fibers contained in the plate-like part.
  • As a target for image processing cut out three plate-like parts that are not directly under the ribs, buff grinding to process the surface roughness to such an extent that the boundary between fiber and resin can be clearly separated when observing the cross section. Digital images taken using a digital microscope were used. The average value of Vf of 3 places obtained by image processing was made into the representative value of Vf of a plate-like part.
  • ⁇ Mean thickness measurement of plate-like part> The four points not directly below the ribs of the plate-like portion were arbitrarily selected and measured with a point contact type micrometer, and the average value was taken as the thickness of the plate-like portion.
  • the thickness of the metal layer was as shown in the catalog value, and was obtained by subtracting the thickness of the metal layer from the thickness of the plate-like portion including the metal layer.
  • the point contact-type micrometer was used in the present Example, the measuring method of the thickness of a plate-like-part can be measured using arbitrary measuring apparatuses.
  • calipers can also be used when the plate-like portion is flat.
  • a method of measuring with a point contact type micrometer is preferably used. If the fiber reinforced plastic structure can not be separated from the fiber reinforced plastic molded article, the thickness of other components of the molded article such as metal may be subtracted as described above, but the catalog value is unknown. In the case, it is possible to use a method in which a cross section of a fiber reinforced plastic molded product including a fiber reinforced plastic structure is cut out and measured with a microscope.
  • the heights of the ribs including the plate-like part were all considered to be the same height in this example, and the calipers were It measured by pinching any rib including a plate-like part, and adopted the measured value.
  • the layer continuous from the plate-like part also penetrates into the rib, and the height reached by the layer is determined by the fact that the fiber existing over both the plate-like part and the rib is the rib It substituted it as height L which reaches inside.
  • L is the difference between the average thickness of the plate-like portion and the distance from the surface having no plate-like rib to the maximum height reached by the continuous layer from the plate-like portion in the rib.
  • the average width of the rib is 30 to 70% in the height direction of the rib in the cross section arbitrarily selected at three positions of 10 to 30%, 30 to 70%, and 70 to 90% from the end of the rib in the longitudinal direction of the rib It was taken as the average value of the width of the place selected one by one from the range of.
  • the width of the rib at each location was measured using a caliper.
  • the vernier caliper was used in the present Example, the method using arbitrary measuring apparatuses can be utilized, for example, a micrometer, a photograph of a cross section, etc. may be acquired, and it may measure by image analysis.
  • the fiber reinforced plastic structural part and the aluminum part were both set to 70 GPa as an approximate value of E except for the comparative example 4.
  • the moment of inertia of area of the fiber-reinforced plastic molded product is calculated using the thickness f (mm) of the plate-like portion, the average width t (mm) of the ribs, the number N of ribs in the cross section, and the height h (mm) of the ribs Calculated by equation 1.
  • the flexural rigidity per unit weight was calculated by dividing EI by the weight of the fiber reinforced plastic molded article.
  • the cross sections for calculating EI are the cross sections shown by lines A and B in FIG. 2, and EI of each cross section is EIA and EIB, EI per unit area of each cross section is EIA per unit area, EIB per unit area .
  • EIA and EIB EI per unit area of each cross section is EIA per unit area, EIB per unit area .
  • Example 1 [0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 90 ° / 0 ° / 90 ° / 0 °] where the lamination configuration of the incised prepreg laminate is 0 ° in the longitudinal direction / 90 ° / 0 °], the upper die is a die having one concave portion, and the lower die is a die having a flat plate-like portion as shown in Tables 1, 2 and 2 (a) in press molding. A fiber-reinforced plastic structure having the shape and characteristics shown in was obtained and used as a fiber-reinforced plastic molded article.
  • Example 2 Except that the lamination configuration of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 90 ° / 0 ° / 90 ° / 0 °] with the longitudinal direction as 0 °
  • a fiber-reinforced plastic structure having the shape and characteristics shown in Tables 1 and 2 and FIG. 2 (a) was obtained by press molding to obtain a fiber-reinforced plastic molded article.
  • Example 1 A molded article lighter in weight than the fiber-reinforced plastic molded article obtained in Example 1 was obtained. Although EIA decreased, it did not bend easily in the direction perpendicular to the cross section of A, and had sufficient rigidity.
  • Example 3 The laminated configuration of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 90 ° / 0 ° / 90 ° / 0 °], with the longitudinal direction at 0 °, and then pressed.
  • the fiber reinforced plastic structure part which has the shape and characteristic shown to Table 1, 2 and FIG. 2 (b) by shaping
  • the upper mold was a mold having two recesses, and the recesses were provided in parallel.
  • the lower mold was a mold in which the plate portion was flat. Although it was about the same weight as the fiber reinforced plastic molded article obtained in Example 2, it has confirmed that EIA was improving.
  • Example 4 The laminated configuration of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 90 ° / 0 ° / 90 ° / 0 °], with the longitudinal direction at 0 °, and then pressed.
  • the upper mold had three concave portions, and the concave portions used molds provided parallel to each other, and the lower mold had a flat plate-like portion. It was confirmed that EIA was further improved than the fiber-reinforced plastic molded product obtained in Example 3.
  • Example 5 The laminated constitution of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 °], with the longitudinal direction at 0 °, and press-formed in Tables 1, 2 and 2 (c).
  • a fiber-reinforced plastic structure having the shape and characteristics shown in was obtained and used as a fiber-reinforced plastic molded article.
  • the upper mold had three concave portions, and the concave portions used molds provided parallel to each other, and the lower mold had a flat plate-like portion.
  • the weight was less than 10 g, it was confirmed that there is a rigidity such that the area directly below the rib would not be dented even when pressed by hand. However, the plate-like portion not immediately below the rib had a feeling of being slightly recessed.
  • Example 6 The laminated constitution of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 °], with the longitudinal direction at 0 °, and press molding as shown in Tables 1, 2 and 2 (d) A fiber-reinforced plastic structure having the shape and characteristics shown in was obtained and used as a fiber-reinforced plastic molded article.
  • the upper mold had seven concave portions, and the concave portions used molds provided parallel to each other, and the lower mold had a flat plate-like portion.
  • the EIA per unit weight was higher than the fiber reinforced plastic molded articles obtained in Examples 1, 2, 3 and 5.
  • the plate-like portion not immediately below the rib was slightly recessed, but in the fiber-reinforced plastic molded article obtained in Example 6, it was possible to indent wherever the plate-like portion was pressed It was not. However, it was easy to bend along the line B direction.
  • Example 7 The laminated configuration of the incised prepreg laminate is [+ 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 °]. It laminated
  • the upper mold used was a mold having two recesses intersecting at right angles, and the lower mold used a mold in which the plate-like part was flat.
  • Example 8 The laminated configuration of the incised prepreg laminate is [+ 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 °].
  • the aluminum was reinforced with the fiber reinforced plastic structure, and it was a molded product having high rigidity.
  • Example 9 The laminated configuration of the incised prepreg laminate is [+ 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 ° / -45 ° / + 45 °].
  • the upper mold was a mold having two concave portions intersecting at right angles, and the lower mold was a mold having a plate-like portion with a curved surface.
  • the longitudinal direction of the prepreg laminate was disposed along one of the grooves provided in the mold, and the obtained fiber-reinforced plastic molded product had a shape as shown in FIG. 3 (a).
  • Example 10 A fiber-reinforced plastic molded article, as in Example 6, except that an aluminum plate having a thickness of 0.5 mm is press-formed and cured to the surface of the plate without the ribs at the same time as the inset prepreg curing. I got
  • Example 11 The laminated constitution of the incised prepreg laminate is laminated at [0 ° / 90 ° / 0 ° / 90 ° / 0 °] with the longitudinal direction as 0 °, and the shape and characteristics shown in Tables 1 and 2 by press molding A fiber-reinforced plastic structure having the same was obtained and used as a fiber-reinforced plastic molded article.
  • the upper mold was a mold having seven recesses, and the recesses were provided in parallel.
  • the lower mold was a mold in which the plate portion became a curved surface.
  • the prepreg laminate was disposed such that the longitudinal direction of the prepreg laminate was along the direction in which the recesses provided in the mold were extended, and the obtained fiber-reinforced plastic molded article had a shape as shown in FIG. 3 (b).
  • Example 12 [0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 90 ° / 0 ° / 90 ° / 0 ° / 90 ° / 0 °] where the lamination configuration of the incised prepreg laminate is 0 ° in the longitudinal direction
  • a fiber-reinforced plastic structure portion having the shape and characteristics shown in Table 1 by press molding in the same manner as in Example 6 except that the ratio is 90 ° / 0 ° / 90 ° / 0 °] is obtained as a fiber reinforced plastic It was a molded article.
  • EAI and EIB were improved as compared with the fiber reinforced plastic molded product obtained in Example 6, the weight was slightly increased.
  • Example 1 The fiber reinforced obtained in Example 2 as an in-cut prepreg laminate having a thickness twice that of Example 2 by stacking two sheets of the same in-cut prepreg laminate as the in-cut prepreg laminate used in Example 2 A thick fiber-reinforced plastic molded article having a plate-like portion was obtained in the same shape as the plastic molded article.
  • EIA was inferior to the fiber reinforced plastic molded article obtained in Example 5, and EIA per unit weight was inferior.
  • Example 5 The press molding was performed using the same mold as that used in Example 4 except that the prepreg laminate was arranged in the mold so that the longitudinal direction of the prepreg laminate intersected at 90 ° with the extending direction of the concave portion provided in the mold. The However, since the fibers and the resin were not filled in the ribs, it was not possible to obtain the same shape as the fiber reinforced plastic molded product obtained in Example 4.
  • Example 6 Three laminated sheets identical to the incised prepreg laminate used in Example 2 were stacked, and an inclining prepreg laminate having a thickness three times the thickness of the incised prepreg laminate used in Example 2 was used.
  • a fiber reinforced plastic structure having the shape and characteristics shown in Table 1 was obtained by press molding to obtain a fiber reinforced plastic molded article.
  • a molded product having a larger average rib width and rib height was obtained.
  • a very high EIA molded product was obtained, but a heavy molded product was obtained despite the fact that the thickness of the plate-like portion was not much different from that of the fiber reinforced plastic molded product obtained in Example 12.
  • Plate-like portion 2 Rib 3: Fiber existing over both plate-like portion and rib 4: Surface without rib of plate-like portion

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  • Chemical & Material Sciences (AREA)
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  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

La présente invention aborde le problème de l'obtention d'un article moulé en plastique renforcé par des fibres, qui est léger et qui présente des caractéristiques mécaniques élevées, par formation de nervures dans une matière plastique renforcée par des fibres à paroi mince. À cet effet, l'article moulé en plastique renforcé par des fibres comprend une structure en matière plastique renforcée par des fibres, la structure en matière plastique renforcée par des fibres comprenant des fibres et une résine, et ayant une partie tabulaire et des nervures faisant saillie à partir d'une surface de la partie tabulaire. La partie tabulaire a une teneur en fibres en volume de 50 à 70 % et une épaisseur moyenne inférieure ou égale à 1,5 mm, et les nervures ont une largeur moyenne de 0,1 à 1,5 mm et comprennent des fibres qui sont présentes dans la partie tabulaire et dans les nervures et qui atteignent une hauteur d'au moins 0,5 mm dans les nervures.
PCT/JP2018/038644 2017-10-20 2018-10-17 Article moulé en plastique renforcé par des fibres WO2019078242A1 (fr)

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JP2021041557A (ja) * 2019-09-06 2021-03-18 積水化学工業株式会社 炭素繊維強化熱可塑性樹脂複合材およびその製造方法
WO2022039226A1 (fr) 2020-08-19 2022-02-24 川崎重工業株式会社 Structure de panneau en matériau composite et son procédé de fabrication
WO2022202600A1 (fr) * 2021-03-26 2022-09-29 東レ株式会社 Stratifié préimprégné, structure composite et procédé de fabrication de structure composite

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JPH0358837A (ja) * 1989-07-28 1991-03-14 Sumitomo Bakelite Co Ltd 複合成形物
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JPWO2012108446A1 (ja) * 2011-02-07 2014-07-03 帝人株式会社 厚みに傾斜のある成形体、およびその製造方法
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JPH0358837A (ja) * 1989-07-28 1991-03-14 Sumitomo Bakelite Co Ltd 複合成形物
JPH04259515A (ja) * 1991-02-13 1992-09-16 Mitsui Toatsu Chem Inc 構造体

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WO2022039226A1 (fr) 2020-08-19 2022-02-24 川崎重工業株式会社 Structure de panneau en matériau composite et son procédé de fabrication
WO2022202600A1 (fr) * 2021-03-26 2022-09-29 東レ株式会社 Stratifié préimprégné, structure composite et procédé de fabrication de structure composite

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