WO2020195828A1 - 繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法 - Google Patents

繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法 Download PDF

Info

Publication number
WO2020195828A1
WO2020195828A1 PCT/JP2020/010531 JP2020010531W WO2020195828A1 WO 2020195828 A1 WO2020195828 A1 WO 2020195828A1 JP 2020010531 W JP2020010531 W JP 2020010531W WO 2020195828 A1 WO2020195828 A1 WO 2020195828A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
fiber
fiber sheet
base material
foam
Prior art date
Application number
PCT/JP2020/010531
Other languages
English (en)
French (fr)
Inventor
忠玄 田中
陽一 平石
中村　崇
裕太 中明
優貴 駒井
Original Assignee
倉敷紡績株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 倉敷紡績株式会社 filed Critical 倉敷紡績株式会社
Priority to KR1020217020660A priority Critical patent/KR20210143158A/ko
Priority to CN202080020679.4A priority patent/CN113573866A/zh
Priority to JP2021509000A priority patent/JPWO2020195828A1/ja
Priority to US17/442,144 priority patent/US20220168931A1/en
Publication of WO2020195828A1 publication Critical patent/WO2020195828A1/ja

Links

Images

Classifications

    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/569—Shaping and joining components with different densities or hardness
    • 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
    • B29C70/84—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 by moulding material on preformed parts to be joined
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
    • C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1209—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements by impregnating a preformed part, e.g. a porous lining
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/30—Expanding the moulding material between endless belts or rollers
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • 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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/321—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements the preformed part being a lining, e.g. a film or a support lining
    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • 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
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • 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
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
    • 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
    • B29C70/78—Moulding material on one side only of the preformed part
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
    • 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
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/34—Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core
    • 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
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/36—After-treatment
    • C08J9/40—Impregnation
    • C08J9/42—Impregnation with macromolecular compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B29K2105/0881—Prepregs unidirectional
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B29K2105/089—Prepregs fabric
    • 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
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/04—Foams characterised by their properties characterised by the foam pores
    • C08J2205/052—Closed cells, i.e. more than 50% of the pores are closed
    • 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
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/10—Rigid foams
    • 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
    • C08J2371/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
    • C08J2371/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08J2371/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • 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
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes

Definitions

  • the present invention relates to a composite in which a fiber reinforced resin and a resin foam are integrated.
  • Fiber reinforced plastic which is resin reinforced with carbon fiber or the like, is known as a lightweight material having high mechanical strength.
  • FRP Fiber reinforced plastic
  • a resin using a thermoplastic resin as the matrix resin may be particularly called a fiber reinforced thermoplastic resin (FRTP) to distinguish it from a resin using a thermosetting resin.
  • a composite in which both are integrated is used for various purposes, with a fiber-reinforced resin having excellent strength as a skin and a lighter resin foam as a core material.
  • a composite has a problem in the adhesiveness between the fiber reinforced resin and the resin foam, and there is a concern that the composite may peel off at the interface between the fiber reinforced resin and the resin foam.
  • Patent Document 1 describes a prepreg in which a twill weave woven fabric made of carbon fibers or the like is impregnated with an uncured epoxy resin or a polyamide 6 resin which is a thermoplastic resin. A resin composite in which a foam sheet such as polyamide 6 is sandwiched between them and heat-bonded is described.
  • Patent Document 2 describes a resin composite in which a foam sheet such as acrylic resin is sandwiched between prepregs obtained by impregnating a twill woven fabric or the like made of carbon fibers with an uncured epoxy resin and heat-bonded.
  • Patent Document 3 describes a method for producing a fiber-reinforced resin sandwich panel by sandwiching a polypropylene foam between prepregs in which unidirectionally aligned carbon fibers are impregnated with an epoxy resin and heat-pressing them.
  • a thermoplastic resin or a thermosetting resin can be used as the resin to be a matrix, and a thermosetting resin is preferably used.
  • a thermosetting resin is used as the resin to be a matrix.
  • the prepreg when a thermoplastic resin is used for the matrix of the fiber reinforced resin, the prepreg is hard and it is difficult to keep the prepreg in a deformed state, so that it is difficult to form a composite having a curved surface.
  • the present invention has been made in consideration of the above, and an object of the present invention is to provide a fiber-reinforced resin composite having high peel strength between a fiber-reinforced resin and a resin foam.
  • the fiber-reinforced resin composite of the present invention is a fiber-reinforced resin composite having a skin and a resin foam, and the resin foam is made of a foamed resin, and the skin is a fiber sheet and a thermoplastic matrix resin. It is characterized by containing the foamed resin continuously impregnated in the epidermis from the resin foam. With this configuration, the skin and the resin foam are strongly integrated, and high peel strength can be obtained between the skin and the resin foam.
  • the fiber sheet is a sheet or woven fabric in which continuous fibers are aligned in one direction. This configuration facilitates the production of the fiber reinforced resin composite.
  • the fiber sheet is made of carbon fiber. This configuration provides lighter weight and higher strength.
  • the matrix resin is a resin selected from the group consisting of phenoxy resin, polyamide 6, polyamide 12, polypropylene, and polycarbonate.
  • the foamed resin is a urethane resin
  • the resin foam is a hard urethane foam.
  • the other fiber-reinforced resin composite of the present invention is a fiber-reinforced resin composite in which a base material in which a fiber sheet made of continuous fibers is partially impregnated with a thermoplastic matrix resin and a resin foam made of a foamed resin are integrated.
  • the base material in which the fiber sheet is partially impregnated with the thermoplastic matrix resin means that the matrix resin is not impregnated in the entire fiber sheet but leaves voids in the fiber sheet. With this configuration, the skin portion including the fiber sheet and the resin foam are strongly integrated, and high peel strength can be obtained between the skin portion and the resin foam.
  • Yet another fiber-reinforced resin composite of the present invention is a fiber-reinforced composite in which a base material in which a thermoplastic matrix resin is fused to the surface of a fiber sheet made of continuous fibers and a resin foam made of a foamed resin are integrated. It is a resin composite.
  • the base material obtained by fusing the thermoplastic matrix resin to the surface of the fiber sheet means that the matrix resin does not penetrate between the fibers constituting the fiber sheet and remains on the outer surface of the fiber sheet.
  • the skin portion including the fiber sheet and the resin foam are strongly integrated, and high peel strength can be obtained between the skin portion and the resin foam.
  • the method for producing a fiber-reinforced resin composite of the present invention includes a step of preparing a base material in which a fiber sheet is partially impregnated with a thermoplastic matrix resin, or a base material in which a thermoplastic matrix resin is fused to the surface of the fiber sheet.
  • the base material and the resin foam are strongly integrated, and high peel strength can be obtained between the skin portion including the fiber sheet and the resin foam.
  • the step of supplying the raw material composition is a step of arranging the base material on the cavity surface of the mold and charging the raw material composition into the cavity of the mold.
  • the step of supplying the raw material composition is the raw material composition while supplying the base material along the first conveyor belt and / or the second conveyor belt of the double belt molding machine. This is a step of putting an object between the first conveyor belt and the second conveyor belt. As a result, a flat plate-shaped composite can be efficiently produced.
  • any of the fiber-reinforced resin composites of the present invention there is no clear interface between the epidermis containing the fiber sheet and the resin foam, and the foamed resin continuously penetrates into the fiber sheet from the resin foam. ing. Due to the anchor effect of this foamed resin, the epidermis and the resin foam are strongly integrated, and high peel strength can be obtained between the epidermis and the resin foam.
  • a base material in which the fiber sheet is partially impregnated with the thermoplastic matrix resin or a base material in which the thermoplastic matrix resin is fused to the surface of the fiber sheet is used.
  • the foamed resin forms the resin foam and at the same time penetrates into the fiber sheet.
  • the fiber-reinforced resin composite 10 of the present embodiment includes a skin 11 and a resin foam 12.
  • the resin foam 12 is made of foamed resin 16.
  • the thickness of the resin foam 12 may be determined according to the required performance, and is not particularly limited.
  • the thickness of the resin foam 12 is typically 5 to 200 mm.
  • the foamed resin 16 constituting the resin foam 12 for example, urethane resin, ABS resin, olefin resin, polyester resin, polystyrene resin, and acrylic resin can be used.
  • the foamed resin 16 is preferably a urethane resin.
  • the resin foam 12 is preferably a hard urethane foam having a closed cell structure. This is because the skin 11 having excellent hardness can be obtained.
  • the closed cell ratio of the rigid urethane foam is preferably 80% or more, more preferably 90% or more.
  • the foaming ratio of the resin foam 12 is preferably 25 times or more.
  • the skin 11 is a fiber-reinforced resin containing a fiber sheet 14, a matrix resin 15 which is a thermoplastic resin, and a foamed resin 16.
  • the skin 11 constitutes one surface 13 of the fiber reinforced resin composite 10.
  • the foamed resin 16 is impregnated in a part or the whole including the vicinity of the interface between the skin 11 and the resin foam 12. When the foamed resin 16 is impregnated in the entire skin 11, the foamed resin may reach the surface 13.
  • the foamed resin 16 is continuously impregnated in the fiber sheet 14 from the resin foam 12. In other words, the portion of the fiber sheet 14 impregnated with the foamed resin 16 and the resin foam 12 are integrally formed at the same time.
  • the skin 11 may be formed on one side of the fiber reinforced resin composite 10 as shown in FIG. 1, or may be formed on both sides of the fiber reinforced resin composite 10.
  • the thickness of the skin 11 may be determined according to the required performance, and is not particularly limited.
  • the thickness of the skin 11 is the thickness of the portion where the matrix resin 15 is present.
  • the thickness of the epidermis 11 is typically 0.05 to 1 mm.
  • the fiber sheet 14 contained in the skin 11 is composed of, for example, carbon fibers, glass fibers, ceramic fibers such as alumina fibers, and metal fibers such as steel fibers.
  • the fiber sheet 14 is preferably made of carbon fiber. This is because it is lighter and has higher strength.
  • the fiber sheet 14 is preferably made of continuous fibers. This is because the strength of the epidermis 11 can be increased.
  • the fiber sheet 14 may be a non-woven fabric, but is preferably a sheet or woven fabric in which continuous fibers are aligned in one direction.
  • the foamed resin 16 is likely to impregnate the fiber sheet 14.
  • the fiber sheet 14 is a sheet in which continuous fibers are aligned in one direction, a plurality of fiber sheets may be superposed so that the length directions of the fibers intersect.
  • the matrix resin 15 of the skin 11 is a thermoplastic resin.
  • a thermoplastic resin such as an olefin resin, a polyester resin, a polyamide resin, an acrylic resin, a phenoxy resin, a sulfide resin, a polycarbonate resin, or a polypropylene resin is used alone or in combination of two or more. Can be used.
  • the matrix resin 15 is preferably a resin selected from the group consisting of phenoxy resin, polyamide 6, polyamide 12, polypropylene, and polycarbonate.
  • the skin 11 is made of a fiber sheet 14, a matrix resin 15, and a foamed resin 16.
  • the fibers of the fiber sheet 14 are filled with the matrix resin 15 and the foamed resin 16.
  • the ratio of the fiber sheet 14 to the skin 11 is preferably 15 to 45% by volume, more preferably 20 to 40% by volume. is there.
  • the thickness of the portion of the skin 11 in which the foamed resin 16 is impregnated into the fiber sheet 14 is the ratio of the foamed resin 16 to the resin components existing between the fibers, that is, , .
  • the thickness of the portion where the foamed resin / (matrix resin + foamed resin) is 40% by volume or more can be defined.
  • the penetration thickness of the foamed resin is preferably 0.1 mm or more or half or more of the thickness of the fiber sheet 14. This is because the larger the penetration thickness of the foamed resin, the higher the peel strength between the skin 11 and the resin foam 12.
  • the penetration thickness of the foamed resin is preferably 1.0 mm or less. This is because even if the penetration thickness of the foamed resin is made thicker than this, the peel strength cannot be further improved.
  • the composition ratio of the components in the skin 11 and the penetration thickness of the foamed resin 16 vary depending on the base material (semi-preg) used for manufacturing.
  • the fiber-reinforced resin composite 10 of the present embodiment integrates a base material in which a fiber sheet 14 made of continuous fibers is partially impregnated with a thermoplastic matrix resin 15 and a resin foam 12 made of a foamed resin 16. Can be.
  • the fiber-reinforced resin composite 10 is a combination of a base material obtained by fusing a thermoplastic matrix resin 15 on the surface of a fiber sheet 14 made of continuous fibers and a resin foam 12 made of a foamed resin 16. Can be. Details of the base material will be described later.
  • the manufacturing method of the present embodiment includes a step of preparing a base material containing a fiber sheet 14 and a thermoplastic matrix resin 15, a step of supplying a raw material composition of a foamed resin 16 to one side of the base material, and a raw material composition. It consists of a foaming process.
  • a base material in which the fiber sheet 14 is partially impregnated with the thermoplastic matrix resin 15 can be used as the base material containing the fiber sheet 14 and the thermoplastic matrix resin 15.
  • the base material in which the fiber sheet is partially impregnated with the matrix resin means a base material in which the matrix resin 15 does not impregnate the entire fiber sheet 14 but exists in the fiber sheet 14 with voids left.
  • Such a substrate is called a semi-preg, as opposed to a prepreg in which the fiber sheet is completely impregnated with the matrix resin.
  • the base material in which the fiber sheet is partially impregnated with the matrix resin is hereinafter referred to as "partially impregnated semipreg".
  • the partially impregnated semipreg can be produced by adhering the powder of the matrix resin 15 to one side or both sides of the fiber sheet 14, softening or melting it by heating, and partially impregnating the fiber sheet 14.
  • the film of the matrix resin 15 may be attached to one or both sides of the fiber sheet 14 and softened or melted by heating to partially impregnate the fiber sheet.
  • the matrix resin 15 is not impregnated into the entire fiber sheet 14, but is manufactured so as to leave voids in the fiber sheet 14.
  • the foamed resin 16 can be impregnated into the fiber sheet 14 in the step of foaming the foamed resin 16 by the voids left between the fibers.
  • the volume ratio of the fiber sheet 14 to the matrix resin 15 is preferably 40:60 to 60:40.
  • a base material in which the thermoplastic matrix resin 15 is fused to the surfaces of one side or both sides of the fiber sheet 14 may be used.
  • the base material in which the thermoplastic matrix resin is fused to the surface of the fiber sheet is a base material in which the matrix resin 15 does not penetrate between the fibers constituting the fiber sheet 14 and remains on the outer surface of the fiber sheet 14. Say. Therefore, the inside of the fiber sheet 14 is in a state where voids are completely left.
  • a base material is also called a semipreg.
  • the base material in which the matrix resin is fused to the surface of the fiber sheet is hereinafter referred to as "surface fusion semipreg".
  • the surface fusion semipreg can be manufactured by the same method as the partially impregnated semipreg.
  • the matrix resin 15 is softened at a lower temperature to the extent that it does not penetrate between the fibers constituting the fiber sheet 14 and fused to the surface of the fiber sheet 14.
  • the volume ratio of the fiber sheet 14 to the matrix resin 15 is preferably 40:60 to 60:40.
  • those having a matrix resin opening formed on the surface and having continuous voids penetrating the semi-pregs in the thickness direction are preferably used.
  • the surface fusion semipreg when comparing the partially impregnated semipreg and the surface fusion semipreg, it is preferable to use the surface fusion semipreg. This is because there are many voids inside the fiber sheet 14, and the foamed resin 16 is easily impregnated into the fiber sheet 14 in the step of foaming the foamed resin 16.
  • the fiber sheet 14 As the fiber sheet 14, as described above, it is preferable to use a sheet or woven fabric in which continuous fibers are aligned in one direction.
  • a sheet in which continuous fibers are aligned in one direction is obtained by opening a bundle of continuous fibers in one direction.
  • the fiber sheet 14 In the surface fusion semipreg using a sheet in which continuous fibers are aligned in one direction, the fiber sheet 14 is easily separated. Therefore, bridge fibers may be arranged on the surface of the fiber sheet 14 and in a direction crossing the fiber sheet 14. ..
  • the same fiber as the fiber sheet 14 main body can be used.
  • the density of the bridge fibers is preferably 25 to 150 fibers per 10 mm 2 of the fiber sheet 14 on average.
  • a known raw material composition of the foamed resin 16 can be used.
  • the foamed resin 16 is a urethane resin
  • a mixed solution of isocyanate and polyol can be used as the raw material composition.
  • This raw material composition is supplied to one side of the semipreg.
  • the resin foam 12 is formed on the side to which the raw material composition of the semipreg is supplied, and the opposite side is the surface 13 of the fiber-reinforced resin composite 10 to be manufactured. Since the ratio of the matrix resin 15 to the fibers is high on the surface to which the powder of the matrix resin 15 is attached when the semipreg is manufactured, if that surface is the surface 13 of the fiber reinforced resin composite 10. , The surface 13 can be obtained more precisely.
  • the foamed resin 16 impregnates the adjacent semi-preg fiber sheet 14 by the foaming pressure while forming the resin foam 12.
  • the fibers of the fiber sheet 14 are filled with the matrix resin 15 and the foamed resin 16 to form a hard skin 11. Further, since the foamed resin 16 is continuously impregnated into the fiber sheet 14 from the resin foam 12, the skin 11 and the resin foam 12 are strongly integrated, and the peel strength between the skin 11 and the resin foam 12 is high. Is obtained.
  • the matrix resin 15 When the softening temperature of the matrix resin 15 is sufficiently low, the matrix resin 15 is heated to a temperature higher than the softening temperature by an external heating means or, when foaming is an exothermic reaction, the reaction heat to soften or melt. The impregnation of the fiber sheet 14 further progresses. In that case, the fiber sheet 14 is completely impregnated with the matrix resin 15 on the surface portion of the semipreg opposite to the resin foam 12, and the surface 13 composed of only the fiber sheet 14 and the matrix resin 15 is obtained.
  • the step of foaming the raw material composition is also a step of integrating the skin 11 of the fiber reinforced resin and the resin foam 12 to form the entire fiber reinforced resin composite 10. This step can be carried out by, for example, a molding method or a double belt molding method.
  • the foamed resin 16 is foamed in the mold.
  • the semipreg is fixed along the cavity surface of either the lower mold and the upper mold of the mold or both.
  • the raw material composition of the foamed resin 16 is put into the cavity of the mold, and the mold is held at an appropriate temperature to foam the raw material composition.
  • the fiber reinforced resin composite 10 having a curved surface can be manufactured by forming the cavity surface of the mold into a curved surface.
  • the double belt type molding machine 30 includes a lower conveyor belt 31 and an upper conveyor belt 32, and face materials 33 and 34 are supplied along the respective conveyor belts. At this time, the semipreg is supplied as one or both of the face materials 33 and 34.
  • the raw material composition is discharged from the raw material tank 35 through the mixing / stirring nozzle 36 onto the face material 33, and is charged between the lower conveyor belt 31 and the upper conveyor belt 32.
  • the raw material composition foams while moving to the right in FIG. 2 according to the movement of the conveyor belts 31 and 32, is sandwiched between the conveyor belts 31 and 32, and is integrally formed with the face materials 33 and 34 into a composite. ..
  • the flat plate-shaped fiber reinforced resin composite 10 can be efficiently manufactured.
  • a semipreg having a thermoplastic resin as a matrix resin is used as a starting material. Since the voids are left in the fiber sheet 14 of the semipreg, the foamed resin 16 can be impregnated in the fiber sheet 14. Further, unlike the prepreg in which the fiber sheet is completely impregnated with the thermoplastic resin, the semi-preg has flexibility, so that it is easy to fix it along the curved surface of the mold in the molding method, and the fiber having a curved surface.
  • the reinforced resin composite 10 can be easily manufactured.
  • the fiber reinforced resin composite of Example 1 was prepared by the following method.
  • a semi-preg powder of phenoxy resin (Nippon Steel Chemical & Materials Co., Ltd., YD-10, Tg: 84 ° C.) on both sides of a sheet (grain: 50 g / m 2 ) in which a unidirectional continuous fiber bundle of carbon fibers is opened.
  • a surface-fused semipreg that was heated and fused was used.
  • the ratio of the phenoxy resin the volume fraction was 50% when the total of the fiber sheet and the phenoxy resin was 100%.
  • Urethane resin was used as the foamed resin.
  • a semi-preg is set on the bottom surface of a lower mold of length 400 mm ⁇ width 400 mm ⁇ cavity thickness 50 mm, and isocyanate (Tosoh Corporation, MR-200) and polyol (Asahi Glass Co., Ltd., EL-450ED) are used as raw material compositions for foamed resin. : 50%, Sanyo Chemical Industries, Ltd., HS-209: 50%) were mixed and injected into the mold. The polyol was blended with a flame retardant, a foaming agent, a foam stabilizer and a catalyst. The lid (upper mold) was closed, the temperature of the mold was maintained at 40 ° C., foaming was performed for 10 minutes, and then the mold was removed.
  • isocyanate Tosoh Corporation, MR-200
  • polyol Asahi Glass Co., Ltd., EL-450ED
  • the obtained resin foam was a hard urethane foam having a density of 43 kg / m 3 , a foaming ratio of 30 times, and a closed cell structure. From the above, the fiber reinforced resin composite of Example 1 was obtained. This fiber-reinforced resin composite has a flat plate shape, and a fiber sheet and a skin containing a phenoxy resin are integrated on one side of a hard urethane foam.
  • the fiber reinforced resin composite of Comparative Example 1 was prepared by the following method.
  • the semipreg used in Example 1 was heated to prepare a prepreg in which the fiber sheet was completely impregnated with the phenoxy resin.
  • the fiber-reinforced resin composite of Comparative Example 1 was prepared in the same manner as in Example 1 thereafter.
  • Both the fiber-reinforced resin composites of Example 1 and Comparative Example 1 had a surface that was hard and had high flexural rigidity. In the fiber-reinforced resin composite of Example 1, it was observed that the urethane resin passed through the fiber sheet and reached the surface.
  • the peel strength between the epidermis and the resin foam was measured according to JIS K6854-1 with respect to the adhesive.
  • Ten samples with a width of 25 mm were cut out from the fiber-reinforced resin composite, and a 90-degree peeling test was performed at a test speed of 100 mm / min.
  • the results are shown in Table 1.
  • the maximum convex point means the maximum value of the peeling force peak during the test
  • the average convex point means the average value of the peaks
  • the average means the average value of the peeling force during the test.
  • Example 1 had a higher peel strength than Comparative Example 1.
  • the fracture state in Example 1, the base material of the resin foam was destroyed in all 10 measurements, and in Comparative Example 1, it was peeled off at the interface between the epidermis and the resin foam in all 10 measurements.
  • the fiber-reinforced resin composite of Example 2 was prepared by the following method. Using the same semipreg, foamed resin, and raw material composition as in Example 1, the semipreg was fixed to the cavity surfaces of the upper and lower molds formed on the curved surface, and the urethane resin was foamed by the same method as in Example 1. As a result, the fiber-reinforced resin composite of Example 2 was obtained, which was corrugated and had the fiber sheet and the skin containing the phenoxy resin integrated on both sides of the rigid urethane foam.
  • Fiber reinforced plastic composite 11 Skin (fiber reinforced plastic) 12 Resin foam 13 Surface 14 Fiber sheet 15 Matrix resin 16 Foam resin 30 Conveyor belt type molding machine 31 Lower conveyor belt (first conveyor belt) 32 Upper conveyor belt (second conveyor belt) 33, 34 Face material 35 Raw material tank 36 Mixing / stirring nozzle

Abstract

［課題］繊維強化樹脂と樹脂発泡体の間の剥離強度が高い繊維強化樹脂複合体を提供する。 ［解決手段］表皮（１１）と樹脂発泡体（１２）とを有する繊維強化樹脂複合体（１０）であって、前記樹脂発泡体が発泡樹脂（１６）からなり、前記表皮が繊維シート（１４）、熱可塑性のマトリクス樹脂（１５）、および前記樹脂発泡体から連続して該表皮中に含浸した前記発泡樹脂（１６）を含むことを特徴とする繊維強化樹脂複合体（１０）。

Description

繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法
　本発明は、繊維強化樹脂と樹脂発泡体が一体化された複合体に関する。
　炭素繊維などで樹脂を強化した繊維強化樹脂（ＦＲＰ）が、軽量で高い機械的強度を有する材料として知られている。一般に、マトリクスとなる樹脂に熱硬化性樹脂を用いるものは比強度に優れることが多く、マトリクスとなる樹脂に熱可塑性樹脂を用いるものは靱性や耐衝撃性に優れることが多い。最近では、高靱性を求めて、後者の開発が盛んに行われている。なお、マトリクス樹脂に熱可塑性樹脂を用いるものは、熱硬化性樹脂を用いるものと区別して、特に繊維強化熱可塑性樹脂（ＦＲＴＰ）と呼ばれることがある。
　また、強度に優れる繊維強化樹脂を表皮とし、より軽量な樹脂発泡体を芯材として、両者を一体化した複合体が様々な用途に使用されている。しかし、かかる複合体には、繊維強化樹脂と樹脂発泡体の接着性に問題があり、繊維強化樹脂と樹脂発泡体の界面で剥離する懸念があった。
　繊維強化樹脂と樹脂発泡体を一体化することに関し、特許文献１には、炭素繊維からなる綾織の織物等に未硬化のエポキシ樹脂または熱可塑性樹脂であるポリアミド６樹脂等を含浸させたプリプレグの間にポリアミド６等の発泡シートを挟んで加熱圧着した樹脂複合体が記載されている。特許文献２には、炭素繊維からなる綾織の織物等に未硬化のエポキシ樹脂を含浸させたプリプレグの間にアクリル樹脂等の発泡シートを挟んで加熱圧着した樹脂複合体が記載されている。特許文献３には、一方向引き揃え炭素繊維にエポキシ樹脂を含浸したプリプレグの間にポリプロピレン発泡体を挟んで加熱圧着することにより、繊維強化樹脂製サンドイッチパネルを製造する方法が記載されている。特許文献１～３はいずれも、マトリクスとなる樹脂として熱可塑性樹脂または熱硬化性樹脂を用いることができ、好ましくは熱硬化性樹脂を用いるとする。特許文献２および３の実施例はすべて、マトリクスとなる樹脂として熱硬化性樹脂を用いている。
再公表特許２０１６－５２６４５号 特開２０１４－２０８４１８号公報 特開２０１２－７６４６４号公報
　特許文献１～３に記載された複合体によれば、プリプレグと樹脂発泡体とを加熱圧着することにより、繊維強化樹脂と樹脂発泡体の剥離強度は改善すると考えられる。しかし、成形された樹脂発泡体を出発材料として用いる限り、繊維強化樹脂と樹脂発泡体の間には明瞭な界面が残り、剥離強度に懸念があった。
　また、繊維強化樹脂のマトリクスに熱可塑性樹脂を採用する場合は、プリプレグが硬く、プリプレグを変形させた状態に保つことが難しいため、曲面を有する複合体の成形が難しかった。
　本発明は、上記を考慮してなされたものであり、繊維強化樹脂と樹脂発泡体の剥離強度が高い繊維強化樹脂複合体を提供することを目的とする。
　本発明の繊維強化樹脂複合体は、表皮と樹脂発泡体とを有する繊維強化樹脂複合体であって、前記樹脂発泡体が発泡樹脂からなり、前記表皮が繊維シートと、熱可塑性のマトリクス樹脂と、前記樹脂発泡体から連続して該表皮中に含浸した前記発泡樹脂とを含むことを特徴とする。この構成によって、表皮と樹脂発泡体が強く一体化され、表皮と樹脂発泡体の間に高い剥離強度が得られる。
　好ましくは、前記繊維シートが連続繊維を一方向に引き揃えたシートまたは織布である。この構成によって、繊維強化樹脂複合体の製造が容易になる。
　好ましくは、前記繊維シートが炭素繊維からなる。この構成によって、より軽量で、より高い強度が得られる。
　好ましくは、前記マトリクス樹脂が、フェノキシ樹脂、ポリアミド６、ポリアミド１２、ポリプロピレン、ポリカーボネートからなる群から選択される樹脂である。
　好ましくは、前記発泡樹脂がウレタン樹脂であり、前記樹脂発泡体が硬質ウレタンフォームである。この構成によって、樹脂発泡体の硬度、反発性等に関する設計の自由度が広がる。
　本発明の他の繊維強化樹脂複合体は、連続繊維からなる繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材と、発泡樹脂からなる樹脂発泡体とを一体化させた繊維強化樹脂複合体である。ここで、繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材とは、マトリクス樹脂が繊維シートの全体に含浸するのではなく、繊維シート中に空隙を残した状態にあるものをいう。この構成によって、繊維シートを含む表皮部分と樹脂発泡体とが強く一体化され、表皮部分と樹脂発泡体の間に高い剥離強度が得られる。
　本発明のさらに他の繊維強化樹脂複合体は、連続繊維からなる繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材と、発泡樹脂からなる樹脂発泡体とを一体化させた繊維強化樹脂複合体である。ここで、繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材とは、マトリクス樹脂が繊維シートを構成する繊維間に侵入するには至らず、繊維シートの外面に留まっているものをいう。この構成によって、繊維シートを含む表皮部分と樹脂発泡体とが強く一体化され、表皮部分と樹脂発泡体の間に高い剥離強度が得られる。
　本発明の繊維強化樹脂複合体の製造方法は、繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材、または繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材を準備する工程と、前記基材の片面に発泡樹脂の原料組成物を供給する工程と、前記原料組成物を発泡させて、前記発泡樹脂からなる樹脂発泡体を形成しながら該発泡樹脂を前記繊維シートの一部に含浸させて、該樹脂発泡体と前記基材とを一体化させる工程とを有する。
　この方法によって、基材と樹脂発泡体とが強く一体化され、繊維シートを含む表皮部分と樹脂発泡体の間に高い剥離強度が得られる。
　上記製造方法において、好ましくは、前記原料組成物を供給する工程が、金型のキャビティ面に前記基材を配置し、前記原料組成物を前記金型のキャビティ内に投入する工程である。これにより、平板状の繊維強化樹脂複合体を製造することもできるし、金型のキャビティ面を曲面に形成すれば、曲面を有する板状の繊維強化樹脂複合体を製造することもできる。
　あるいは、上記製造方法において、好ましくは、前記原料組成物を供給する工程が、ダブルベルト成形機の第１コンベアベルトおよび／または第２コンベアベルトに沿って前記基材を供給しながら、前記原料組成物を前記第１コンベアベルトと前記第２コンベアベルトの間に投入する工程である。これにより、平板状の複合体を効率良く製造できる。
　本発明のいずれかの繊維強化樹脂複合体によれば、繊維シートを含む表皮と樹脂発泡体との間に明瞭な界面がなく、発泡樹脂が樹脂発泡体から連続して繊維シート中に侵入している。この発泡樹脂によるアンカー効果によって、表皮と樹脂発泡体とが強く一体化され、表皮と樹脂発泡体の間に高い剥離強度が得られる。
　本発明の繊維強化樹脂複合体の製造方法によれば、繊維シートに熱可塑性のマトリクス樹脂が部分含浸した基材、または繊維シートの表面に熱可塑性のマトリクス樹脂が融着した基材を用いるので、原料組成物を発泡させる工程において、発泡樹脂が樹脂発泡体を形成すると同時に繊維シート中に侵入する。その結果、発泡樹脂によるアンカー効果によって、繊維シートを含む表皮部分と基材と樹脂発泡体とが強く一体化され、繊維シートを含む表皮部分と樹脂発泡体の間の剥離強度の高い繊維強化樹脂複合体が得られる。
一実施形態の繊維強化樹脂複合体の断面構造を示す図である。 一実施形態の繊維強化樹脂複合体のダブルベルト成形法を説明するための図である。
　図１を参照して、本実施形態の繊維強化樹脂複合体１０は、表皮１１と、樹脂発泡体１２とからなる。
　樹脂発泡体１２は、発泡した発泡樹脂１６からなる。樹脂発泡体１２の厚さは、要求される性能に応じて決定すればよく、特に限定されない。樹脂発泡体１２の厚さは典型的には５～２００ｍｍである。
　樹脂発泡体１２を構成する発泡樹脂１６としては、例えば、ウレタン樹脂、ＡＢＳ樹脂、オレフィン系樹脂、ポリエステル系樹脂、ポリスチレン樹脂、アクリル系樹脂を用いることができる。発泡樹脂１６は、好ましくはウレタン樹脂である。ウレタン樹脂の発泡体は、原料成分の配合を変えることで、硬度、弾性、反発性、吸音性等の特性を広く調整できるので、繊維強化樹脂複合体１０の製品設計の自由度が広がるからである。また、樹脂発泡体１２は好ましくは独立気泡構造を有する硬質ウレタンフォームである。これにより、硬度に優れた表皮１１が得られるからである。硬質ウレタンフォームの独立気泡率は、好ましくは８０％以上、より好ましくは９０％以上である。また、樹脂発泡体１２の発泡倍率は好ましくは２５倍以上である。
　表皮１１は、繊維シート１４と熱可塑性樹脂であるマトリクス樹脂１５と発泡樹脂１６を含む繊維強化樹脂である。表皮１１は繊維強化樹脂複合体１０の一表面１３を構成している。発泡樹脂１６は表皮１１の樹脂発泡体１２との界面近傍を含む一部または全体に含浸している。発泡樹脂１６が表皮１１全体に含浸している場合には、発泡樹脂が表面１３にまで到達していてもよい。発泡樹脂１６は樹脂発泡体１２から連続して繊維シート１４中に含浸している。言い換えると、発泡樹脂１６が繊維シート１４中に含浸した部分と樹脂発泡体１２とは、一体として同時に形成されている。
　表皮１１は、図１に示したように繊維強化樹脂複合体１０の片面に形成されていてもよいし、繊維強化樹脂複合体１０の両面に形成されていてもよい。
　表皮１１の厚さは、要求される性能に応じて決定すればよく、特に限定されない。表皮１１の厚さとは、マトリクス樹脂１５の存在する部分の厚さである。表皮１１の厚さは典型的には０．０５～１ｍｍである。
　表皮１１に含まれる繊維シート１４は、例えば、炭素繊維、ガラス繊維、アルミナ繊維などのセラミクス繊維、スチール繊維などの金属繊維から構成される。繊維シート１４は、好ましくは炭素繊維からなる。より軽量で、より高い強度が得られるからである。
　繊維シート１４は、好ましくは連続繊維からなる。表皮１１の強度を高くできるからである。繊維シート１４が連続繊維からなる場合、繊維シート１４は不織布であってもよいが、好ましくは連続繊維を一方向に引き揃えたシートまたは織布である。繊維強化樹脂複合体１０を製造する際に発泡樹脂１６が繊維シート１４に含浸しやすい。繊維シート１４が連続繊維を一方向に引き揃えたシートである場合、繊維の長さ方向が交差するように、複数の繊維シートを重ね合わせて用いてもよい。
　表皮１１のマトリクス樹脂１５は熱可塑性樹脂である。マトリクス樹脂１５としては、オレフィン系樹脂、ポリエステル系樹脂、ポリアミド系樹脂、アクリル系樹脂、フェノキシ樹脂、サルファイド系樹脂、ポリカーボネート系樹脂、ポリプロピレン系樹脂などの熱可塑性樹脂を単独で、または複数混合して用いることができる。マトリクス樹脂１５は、好ましくは、フェノキシ樹脂、ポリアミド６、ポリアミド１２、ポリプロピレン、ポリカーボネートからなる群から選択される樹脂である。
　表皮１１は、繊維シート１４、マトリクス樹脂１５および発泡樹脂１６からなる。繊維シート１４の繊維の間はマトリクス樹脂１５および発泡樹脂１６によって埋められている。表皮１１に占める繊維シート１４の割合（繊維体積含有率）、すなわち、繊維／（繊維＋マトリクス樹脂＋発泡樹脂）は、好ましくは１５～４５体積％であり、より好ましくは２０～４０体積％である。
　表皮１１中で、発泡樹脂１６が繊維シート１４に含浸した部分の厚さ（以下、「発泡樹脂の侵入厚さ」という）は、繊維間に存在する樹脂成分に占める発泡樹脂１６の割合、すなわち、発泡樹脂／（マトリクス樹脂＋発泡樹脂）が４０体積％以上である部分の厚さと定義できる。発泡樹脂の侵入厚さは、好ましくは０．１ｍｍ以上または繊維シート１４の厚さの半分以上である。発泡樹脂の侵入厚さが大きいほど、表皮１１と樹脂発泡体１２の間の剥離強度を高められるからである。一方、発泡樹脂の侵入厚さは、好ましくは１．０ｍｍ以下である。発泡樹脂の侵入厚さをこれ以上厚くしても剥離強度のさらなる向上が得られないからである。
　表皮１１中の成分の構成比や発泡樹脂１６の侵入厚さは、製造に用いる基材（セミプレグ）によって変化する。本実施形態の繊維強化樹脂複合体１０は、連続繊維からなる繊維シート１４に熱可塑性のマトリクス樹脂１５を部分含浸した基材と、発泡樹脂１６からなる樹脂発泡体１２とを一体化させたものとすることができる。あるいは、繊維強化樹脂複合体１０は、連続繊維からなる繊維シート１４の表面に熱可塑性のマトリクス樹脂１５を融着した基材と、発泡樹脂１６からなる樹脂発泡体１２とを一体化させたものとすることができる。基材の詳細は後述する。
　次に、本実施形態の繊維強化樹脂複合体１０の製造方法を説明する。
　本実施形態の製造方法は、繊維シート１４と熱可塑性のマトリクス樹脂１５を含む基材を準備する工程と、基材の片面に発泡樹脂１６の原料組成物を供給する工程と、原料組成物を発泡させる工程からなる。
　繊維シート１４と熱可塑性のマトリクス樹脂１５を含む基材としては、例えば、繊維シート１４に熱可塑性のマトリクス樹脂１５を部分含浸した基材を用いることができる。繊維シートにマトリクス樹脂が部分含浸した基材とは、マトリクス樹脂１５が繊維シート１４の全体に含浸するのではなく、繊維シート１４中に空隙を残した状態で存在する基材をいう。このような基材は、マトリクス樹脂が繊維シートに完全に含浸したプリプレグに対して、セミプレグと呼ばれる。繊維シートにマトリクス樹脂が部分含浸した基材を以下において「部分含浸セミプレグ」という。
　部分含浸セミプレグは、マトリクス樹脂１５の粉末を繊維シート１４の片面または両面に付着させ、加熱により軟化または融解させて繊維シート１４に部分的に含浸させることによって製造できる。あるいは、マトリクス樹脂１５のフィルムを繊維シート１４の片面または両面に貼り付け、加熱により軟化または融解させて繊維シートに部分的に含浸させることによって製造してもよい。このとき、マトリクス樹脂１５が繊維シート１４の全体に含浸するのではなく、繊維シート１４中に空隙を残した状態となるように製造される。繊維間に残された空隙により、発泡樹脂１６を発泡させる工程で、発泡樹脂１６が繊維シート１４中に含浸できる。繊維シート１４とマトリクス樹脂１５の体積比は、好ましくは４０：６０～６０：４０である。
　また、繊維シート１４と熱可塑性のマトリクス樹脂１５を含む基材として、繊維シート１４の片側または両側の表面に熱可塑性のマトリクス樹脂１５を融着した基材を用いてもよい。繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材とは、マトリクス樹脂１５が繊維シート１４を構成する繊維間に侵入するには至らず、繊維シート１４の外面に留まっているものをいう。したがって、繊維シート１４の内部は空隙が完全に残された状態にある。このような基材もセミプレグと呼ばれる。繊維シートの表面にマトリクス樹脂を融着した基材を以下において「表面融着セミプレグ」という。
　表面融着セミプレグは、部分含浸セミプレグと同様の方法で製造できる。ただし、マトリクス樹脂１５をより低温で、繊維シート１４を構成する繊維間には侵入しない程度に軟化させて、繊維シート１４の表面に融着させる。繊維シート１４とマトリクス樹脂１５の体積比は、好ましくは４０：６０～６０：４０である。
　上記各種のセミプレグのうち、好ましくは、表面にマトリクス樹脂の開口が形成され、セミプレグを厚さ方向に貫通する連続した空隙が存在するものを用いる。具体的には、繊維シート１４の表面にマトリクス樹脂の粉末を付着させて製造したセミプレグを用いるのが好ましい。発泡樹脂１６を発泡させる工程で、ガスがセミプレグを透過することで、発泡樹脂１６が繊維シート１４中に含浸しやすいからである。また、部分含浸セミプレグと表面融着セミプレグを比較すると、表面融着セミプレグを用いるのが好ましい。繊維シート１４内部の空隙が多く、発泡樹脂１６を発泡させる工程で、発泡樹脂１６が繊維シート１４中に含浸しやすいからである。
　繊維シート１４としては、前述のとおり、連続繊維を一方向に引き揃えたシートまたは織布を用いることが好ましい。連続繊維を一方向に引き揃えたシートは、一方向連続繊維束を開繊することによって得られる。連続繊維を一方向に引き揃えたシートを用いた表面融着セミプレグでは、繊維シート１４がばらけやすいので、繊維シート１４の表面にかつ繊維シート１４を横切る方向にブリッジファイバーを配してもよい。ブリッジファイバーとしては、繊維シート１４本体と同じ繊維を用いることができる。ブリッジファイバーの密度は、好ましくは、繊維シート１４の面積１０ｍｍ２あたり平均２５～１５０本である。
　発泡樹脂１６の原料組成物は公知のものを用いることができる。例えば、発泡樹脂１６がウレタン樹脂である場合は、原料組成物としてイソシアネートとポリオールの混合液を用いることができる。この原料組成物をセミプレグの片面に供給する。セミプレグの原料組成物を供給した側に樹脂発泡体１２が形成され、その反対側が製造される繊維強化樹脂複合体１０の表面１３となる。セミプレグを製造する際にマトリクス樹脂１５の粉末を付着させた面は、繊維に対するマトリクス樹脂１５の割合が高くなっているので、その面が繊維強化樹脂複合体１０の表面１３となるようにすれば、より緻密に表面１３が得られる。
　原料組成物を発泡させる工程において、発泡樹脂１６は樹脂発泡体１２を形成しながら、発泡圧によって隣接するセミプレグの繊維シート１４に含浸する。繊維シート１４の繊維間がマトリクス樹脂１５および発泡樹脂１６で埋められて、硬い表皮１１が形成される。また、発泡樹脂１６が樹脂発泡体１２から連続して繊維シート１４中に含浸するので、表皮１１と樹脂発泡体１２とが強く一体化され、表皮１１と樹脂発泡体１２の間に高い剥離強度が得られる。
　マトリクス樹脂１５の軟化温度が十分に低い場合には、外部からの加熱手段や、発泡が発熱反応である場合はその反応熱によってマトリクス樹脂１５が軟化温度以上に加熱されて軟化または融解して、繊維シート１４への含浸がさらに進行する。その場合、セミプレグの樹脂発泡体１２と反対側の表面部分では繊維シート１４にマトリクス樹脂１５が完全に含浸し、繊維シート１４とマトリクス樹脂１５のみからなる表面１３が得られる。
　原料組成物を発泡させる工程は、繊維強化樹脂の表皮１１と樹脂発泡体１２を一体化して、繊維強化樹脂複合体１０の全体を成形する工程でもある。この工程は、例えば、モールド成形法やダブルベルト成形法によって実施できる。
　モールド成形法では、金型内で発泡樹脂１６を発泡させる。金型の下型のおよび上型のいずれか一方または両方のキャビティ面に沿わせて、セミプレグを固定する。金型のキャビティ内に発泡樹脂１６の原料組成物を投入し、金型を適当な温度に保持して、原料組成物を発泡させる。モールド成形法によれば、金型のキャビティ面を曲面に形成することにより、曲面を有する繊維強化樹脂複合体１０を製造できる。
　ダブルベルト成形法では、一対のコンベアベルト間で樹脂を発泡させる。図２を参照して、ダブルベルト方式の成形機３０は、下コンベアベルト３１と上コンベアベルト３２を備え、それぞれのコンベアベルトに沿って面材３３、３４が供給される。このとき、面材３３、３４の一方または両方としてセミプレグを供給する。原料組成物が原料タンク３５から混合・撹拌ノズル３６を経て面材３３上に吐出されることにより、下コンベアベルト３１と上コンベアベルト３２の間に投入される。原料組成物はコンベアベルト３１、３２の動きに従って図２の右方向へ移動しながら発泡し、コンベアベルト３１、３２に挟まれて、面材３３、３４と一体となって複合体に成形される。ダブルベルト成形法によれば、平板状の繊維強化樹脂複合体１０を効率良く製造できる。
　本実施形態の製造方法では、熱可塑性樹脂をマトリクス樹脂とするセミプレグを出発材料として用いる。セミプレグの繊維シート１４中には空隙が残されているため、発泡樹脂１６が繊維シート１４中に含浸できる。また、熱可塑性樹脂を繊維シートに完全に含浸させたプリプレグと異なり、セミプレグは柔軟性を有するため、モールド成形法において、金型の曲面に沿わせて固定することが容易で、曲面を有する繊維強化樹脂複合体１０の製造が容易である。
　実施例１の繊維強化樹脂複合体を次の方法によって作製した。セミプレグとして、炭素繊維の一方向連続繊維束を開繊したシート（目付：５０ｇ／ｍ２）の両面にフェノキシ樹脂（日鉄ケミカル＆マテリアル株式会社、ＹＤ－１０、Ｔｇ：８４℃）の粉体を塗布して、加熱して融着させた表面融着セミプレグを用いた。フェノキシ樹脂の割合は、繊維シートとフェノキシ樹脂の合計を１００％としたときの体積分率が５０％であった。発泡樹脂としてはウレタン樹脂を用いた。縦４００ｍｍ×横４００ｍｍ×キャビティ厚さ５０ｍｍの下型の底面にセミプレグをセットし、発泡樹脂の原料組成物として、イソシアネート（東ソー株式会社、ＭＲ－２００）と、ポリオール（旭硝子株式会社、ＥＬ－４５０ＥＤ：５０％、三洋化成工業株式会社、ＨＳ－２０９：５０％）の２液を混合して金型に注入した。ポリオールには難燃剤、発泡剤、整泡剤および触媒を配合した。蓋（上型）を閉じて、金型の温度を４０℃に保持して１０分間発泡させた後、脱型した。得られた樹脂発泡体は、密度４３ｋｇ／ｍ３、発泡倍率３０倍、独立気泡構造を有する硬質ウレタンフォームであった。以上により、実施例１の繊維強化樹脂複合体が得られた。この繊維強化樹脂複合体は、平板状で、硬質ウレタンフォームの片面に繊維シートとフェノキシ樹脂を含む表皮が一体化されたものである。
　比較例１の繊維強化樹脂複合体を次の方法によって作製した。実施例１で用いたセミプレグを加熱して、フェノキシ樹脂を繊維シートに完全に含浸したプリプレグを作製した。このプリプレグを用いて、以後は実施例１と同じ方法で、比較例１の繊維強化樹脂複合体を作製した。
　実施例１および比較例１の繊維強化樹脂複合体はいずれも、硬く、曲げ剛性の高い表面を有していた。実施例１の繊維強化樹脂複合体では、ウレタン樹脂が繊維シートを通過して表面に達していることが観察できた。
　実施例１および比較例１の繊維強化樹脂複合体について、表皮と樹脂発泡体の剥離強度を、接着剤に対するＪＩＳＫ６８５４－１に準拠して測定した。繊維強化樹脂複合体から幅２５ｍｍのサンプルを１０本切り出し、試験速度１００ｍｍ／分で、９０度剥離試験を行った。結果を表１に示す。表１中、凸最大点は試験中の剥離力のピークの最大値、凸点平均は同じくピークの平均値、平均は試験中の剥離力の平均値を意味する。
Figure JPOXMLDOC01-appb-T000001
　表１から、実施例１の方が比較例１より剥離強度が大きいことが確認できた。破壊状況は、実施例１では１０回の測定すべてで樹脂発泡体の母材が破壊し、比較例１では１０回の測定すべてで表皮と樹脂発泡体の界面で剥離した。
　次に、実施例２の繊維強化樹脂複合体を次の方法によって作製した。実施例１と同じセミプレグ、発泡樹脂、原料組成物を用い、曲面に形成した上型および下型のキャビティ面にセミプレグを固定して、実施例１と同じ方法でウレタン樹脂を発泡させた。これにより、波板状で、硬質ウレタンフォームの両面に上記繊維シートとフェノキシ樹脂を含む表皮が一体化された、実施例２の繊維強化樹脂複合体が得られた。
　この方法により、曲面を有する複合体が製造できることを確認した。実施例２の繊維強化樹脂複合体でも、実施例１と同様に、ウレタン樹脂が繊維シートを通過して表面に達していることが観察できた。
　１０　繊維強化樹脂複合体
　１１　表皮（繊維強化樹脂）
　１２　樹脂発泡体
　１３　表面
　１４　繊維シート
　１５　マトリクス樹脂
　１６　発泡樹脂
　３０　コンベアベルト方式の成形機
　３１　下コンベアベルト（第１コンベアベルト）
　３２　上コンベアベルト（第２コンベアベルト）
　３３、３４　面材
　３５　原料タンク
　３６　混合・撹拌ノズル

Claims (12)

  1. 　表皮と樹脂発泡体とを有する繊維強化樹脂複合体であって、
    　前記樹脂発泡体が発泡樹脂からなり、
    　前記表皮が繊維シート、熱可塑性のマトリクス樹脂、および前記樹脂発泡体から連続して該表皮中に含浸した前記発泡樹脂を含むことを特徴とする、
    繊維強化樹脂複合体。
  2. 　前記繊維シートが連続繊維を一方向に引き揃えたシートまたは織布である、
    請求項１に記載の繊維強化樹脂複合体。
  3. 　前記繊維シートが炭素繊維からなる、
    請求項１または２に記載の繊維強化樹脂複合体。
  4. 　前記マトリクス樹脂が、フェノキシ樹脂、ポリアミド６、ポリアミド１２、ポリプロピレン、ポリカーボネートからなる群から選択される樹脂である、
    請求項１～３のいずれか一項に記載の繊維強化樹脂複合体。
  5. 　前記発泡樹脂がウレタン樹脂であり、前記樹脂発泡体が硬質ウレタンフォームである、
    請求項１～４のいずれか一項に記載の繊維強化樹脂複合体。
  6. 　連続繊維からなる繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材と、発泡樹脂からなる樹脂発泡体とを一体化させた繊維強化樹脂複合体。
  7. 　連続繊維からなる繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材と、発泡樹脂からなる樹脂発泡体とを一体化させた繊維強化樹脂複合体。
  8. 　繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材、または繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材を準備する工程と、
    　前記基材の片面に発泡樹脂の原料組成物を供給する工程と、
    　前記原料組成物を発泡させて、前記発泡樹脂からなる樹脂発泡体を形成しながら該発泡樹脂を前記繊維シートの一部に含浸させて、該樹脂発泡体と前記基材とを一体化させる工程と、
    を有する繊維強化樹脂複合体の製造方法。
  9. 　前記基材が、繊維シートに熱可塑性のマトリクス樹脂を部分含浸した基材である、
    請求項８に記載の繊維強化樹脂複合体の製造方法。
  10. 　前記基材が、繊維シートの表面に熱可塑性のマトリクス樹脂を融着した基材である、
    請求項８に記載の繊維強化樹脂複合体の製造方法。
  11. 　前記原料組成物を供給する工程が、金型のキャビティ面に前記基材を配置し、前記原料組成物を前記金型のキャビティ内に投入する工程である、
    請求項８～１０のいずれか一項に記載の繊維強化樹脂複合体の製造方法。
  12. 　前記原料組成物を供給する工程が、ダブルベルト成形機の第１コンベアベルトおよび／または第２コンベアベルトに沿って前記基材を供給しながら、前記原料組成物を前記第１コンベアベルトと前記第２コンベアベルトの間に投入する工程である、
    請求項８～１０のいずれか一項に記載の繊維強化樹脂複合体の製造方法。
PCT/JP2020/010531 2019-03-27 2020-03-11 繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法 WO2020195828A1 (ja)

Priority Applications (4)

Application Number Priority Date Filing Date Title
KR1020217020660A KR20210143158A (ko) 2019-03-27 2020-03-11 섬유 강화 수지 복합체 및 섬유 강화 수지 복합체의 제조 방법
CN202080020679.4A CN113573866A (zh) 2019-03-27 2020-03-11 纤维强化树脂复合体及纤维强化树脂复合体的制造方法
JP2021509000A JPWO2020195828A1 (ja) 2019-03-27 2020-03-11
US17/442,144 US20220168931A1 (en) 2019-03-27 2020-03-11 Fiber-reinforced resin composite and method for producing fiber-reinforced resin composite

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2019-061684 2019-03-27
JP2019061684 2019-03-27

Publications (1)

Publication Number Publication Date
WO2020195828A1 true WO2020195828A1 (ja) 2020-10-01

Family

ID=72610572

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2020/010531 WO2020195828A1 (ja) 2019-03-27 2020-03-11 繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法

Country Status (6)

Country Link
US (1) US20220168931A1 (ja)
JP (1) JPWO2020195828A1 (ja)
KR (1) KR20210143158A (ja)
CN (1) CN113573866A (ja)
TW (1) TW202039650A (ja)
WO (1) WO2020195828A1 (ja)

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH06155599A (ja) * 1992-11-26 1994-06-03 Sumitomo Chem Co Ltd 繊維強化樹脂製品およびその製造方法
JP2010284986A (ja) * 2009-06-09 2010-12-24 Nagoya Oil Chem Co Ltd 吸音性積層材および吸音性積層材成形物
JP2011224873A (ja) * 2010-04-20 2011-11-10 Mitsubishi Plastics Inc 繊維強化樹脂製サンドイッチ構造体
JP2012076464A (ja) 2004-03-29 2012-04-19 Toray Ind Inc 繊維強化樹脂製サンドイッチパネルの製造方法
JP2013035247A (ja) * 2011-08-10 2013-02-21 Toyota Motor Corp 繊維強化樹脂成形体及びそれを用いた車両用内装材
WO2014010106A1 (ja) * 2012-07-12 2014-01-16 株式会社イノアックコーポレーション 炭素繊維強化複合材及びその製造方法
JP2014208418A (ja) 2013-03-29 2014-11-06 積水化成品工業株式会社 繊維強化複合体及びその製造方法
JP2015003445A (ja) * 2013-06-20 2015-01-08 呉羽テック株式会社 自動車内装材用不織布及びその製造方法
JP2016052645A (ja) 2014-09-04 2016-04-14 ニッタ株式会社 フィルタ枠およびエアフィルタ
JP2018510796A (ja) * 2015-03-16 2018-04-19 ロジャーズ コーポレーション ポリマー発泡体複合材の製造方法、それにより調製されたポリマー発泡体複合材、及びそれから調製された物品
WO2018159597A1 (ja) * 2017-02-28 2018-09-07 宇部エクシモ株式会社 繊維強化発泡粒子成形体、およびその製造方法

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0872119A (ja) * 1994-06-30 1996-03-19 Isuzu Motors Ltd Ｆｒｐ積層体の製造方法
KR20160052645A (ko) 2013-09-06 2016-05-12 엔테그리스, 아이엔씨. 개선된 고체 게터를 갖춘 기판 격납고

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH06155599A (ja) * 1992-11-26 1994-06-03 Sumitomo Chem Co Ltd 繊維強化樹脂製品およびその製造方法
JP2012076464A (ja) 2004-03-29 2012-04-19 Toray Ind Inc 繊維強化樹脂製サンドイッチパネルの製造方法
JP2010284986A (ja) * 2009-06-09 2010-12-24 Nagoya Oil Chem Co Ltd 吸音性積層材および吸音性積層材成形物
JP2011224873A (ja) * 2010-04-20 2011-11-10 Mitsubishi Plastics Inc 繊維強化樹脂製サンドイッチ構造体
JP2013035247A (ja) * 2011-08-10 2013-02-21 Toyota Motor Corp 繊維強化樹脂成形体及びそれを用いた車両用内装材
WO2014010106A1 (ja) * 2012-07-12 2014-01-16 株式会社イノアックコーポレーション 炭素繊維強化複合材及びその製造方法
JP2014208418A (ja) 2013-03-29 2014-11-06 積水化成品工業株式会社 繊維強化複合体及びその製造方法
JP2015003445A (ja) * 2013-06-20 2015-01-08 呉羽テック株式会社 自動車内装材用不織布及びその製造方法
JP2016052645A (ja) 2014-09-04 2016-04-14 ニッタ株式会社 フィルタ枠およびエアフィルタ
JP2018510796A (ja) * 2015-03-16 2018-04-19 ロジャーズ コーポレーション ポリマー発泡体複合材の製造方法、それにより調製されたポリマー発泡体複合材、及びそれから調製された物品
WO2018159597A1 (ja) * 2017-02-28 2018-09-07 宇部エクシモ株式会社 繊維強化発泡粒子成形体、およびその製造方法

Also Published As

Publication number Publication date
KR20210143158A (ko) 2021-11-26
TW202039650A (zh) 2020-11-01
CN113573866A (zh) 2021-10-29
US20220168931A1 (en) 2022-06-02
JPWO2020195828A1 (ja) 2020-10-01

Similar Documents

Publication Publication Date Title
US11241867B2 (en) Multicomponent polymer resin, methods for applying the same, and composite laminate structure including the same
US5518796A (en) Near-surface enhancement of honeycomb sandwich structures to improve durability using a foaming fiber-filled adhesive
US9505177B2 (en) Method for producing a metal composite
CN107257820B (zh) 纤维增强的各向异性泡沫体
EP3394157B1 (en) Reinforced foam structure, and associated method of forming, and article
CN112969575B (zh) 高强度低热释放复合材料
CN112955314B (zh) 包括具有sp2碳材料的树脂层的高强度低热释放部件
WO2020195828A1 (ja) 繊維強化樹脂複合体、および繊維強化樹脂複合体の製造方法
WO2022209454A1 (ja) 扁平軽量部材およびその製造方法
JP5864324B2 (ja) 繊維強化複合体の製造方法
US20230040874A1 (en) Fiber-reinforced composite material and sandwich structure
WO2021200008A1 (ja) 繊維強化プラスチック成形体
US11833803B2 (en) Fiber reinforced plastic molded body
JPH08276524A (ja) 多孔質コアを有する複合成形品の製造方法
JP7030622B2 (ja) 複合材料構造体及びその形成方法
JP2021112849A (ja) 積層体及び積層体の製造方法
JP6877264B2 (ja) 繊維強化複合材料積層体
JP2004338270A (ja) 繊維強化樹脂複合材料の製造方法および繊維強化樹脂複合材料
TW201834842A (zh) 纖維強化複合體
JPH0740490A (ja) 繊維強化樹脂複合体
WO2022209455A1 (ja) 扁平軽量部材およびその製造方法
US11926088B2 (en) Prepreg, preform, fiber-reinforced composite material, and method for producing said prepreg, said preform or said fiber-reinforced composite material
JP2021049692A (ja) 繊維強化複合パネル
WO2023204132A1 (ja) 樹脂成形体およびその製造方法
JP2022063509A (ja) 繊維強化サンドイッチ複合体

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 20776748

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 2021509000

Country of ref document: JP

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 2020776748

Country of ref document: EP

Effective date: 20211027

122 Ep: pct application non-entry in european phase

Ref document number: 20776748

Country of ref document: EP

Kind code of ref document: A1