WO2021095626A1 - 真空成形用樹脂一体化繊維シート、これを用いた成形体と成形体の製造方法 - Google Patents

真空成形用樹脂一体化繊維シート、これを用いた成形体と成形体の製造方法 Download PDF

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Publication number
WO2021095626A1
WO2021095626A1 PCT/JP2020/041330 JP2020041330W WO2021095626A1 WO 2021095626 A1 WO2021095626 A1 WO 2021095626A1 JP 2020041330 W JP2020041330 W JP 2020041330W WO 2021095626 A1 WO2021095626 A1 WO 2021095626A1
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Prior art keywords
resin
fiber
fiber sheet
integrated
vacuum
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Ceased
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PCT/JP2020/041330
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English (en)
French (fr)
Japanese (ja)
Inventor
田中忠玄
中村崇
平石陽一
中明裕太
駒井優貴
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Kurashiki Spinning Co Ltd
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Kurashiki Spinning Co Ltd
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Priority to CN202080078377.2A priority Critical patent/CN114728439B/zh
Priority to JP2021556052A priority patent/JP7519374B2/ja
Priority to US17/775,724 priority patent/US12319047B2/en
Priority to EP20886341.5A priority patent/EP4059684A4/en
Publication of WO2021095626A1 publication Critical patent/WO2021095626A1/ja
Anticipated expiration legal-status Critical
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    • 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
    • B32B5/26—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 another layer next to it also being fibrous or filamentary
    • B32B5/265—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 another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
    • B32B5/266—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 another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
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    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • 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
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
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Definitions

  • the present invention relates to a resin-integrated fiber sheet for vacuum forming using a semi-preg, a molded body using the same, and a method for manufacturing the molded body.
  • Carbon fiber which is a reinforcing fiber material, is composited with various matrix resins, and the obtained fiber reinforced plastic has come to be widely used in various fields and applications.
  • unidirectional continuous fibers using a thermoplastic resin as a matrix resin are used.
  • a prepreg in which a carbon fiber base material is completely impregnated with a resin has been used, and it has been suggested that the impact resistance when used as a composite material is excellent, the molding time is short, and the molding cost can be reduced.
  • Semipreg is an unimpregnated base sheet in which the matrix resin is adhered / fused onto the fiber base material or in a semi-impregnated state, and is soft and has excellent shapeability. In addition, since molding can be performed directly, molding efficiency is also excellent.
  • Patent Document 1 discloses a base material in which a non-woven fabric is produced and a film is laminated on the outermost layer. Although such a base material is excellent for transportation and the like, it is difficult to use it for continuous fibers because a step of processing the reinforcing fibers into a non-woven fabric is required. Further, there is a problem that the manufacturing conditions of the base material are determined in order to bond the films, and the mass of the base material cannot be set arbitrarily. Further, when the film is in the outermost layer, the base material becomes hard and a problem arises in formability.
  • Patent Document 2 discloses an apparatus for manufacturing a molded product of a prepreg using a prepreg or a semi-preg, but there is a problem with a molding method.
  • the present invention provides a resin-integrated fiber sheet for vacuum forming, which has excellent shapeability and does not cause voids, and a molded body and a method for manufacturing the molded body using the same.
  • the resin-integrated fiber sheet for vacuum forming of the present invention is a resin-integrated fiber sheet for vacuum forming for obtaining a fiber-reinforced resin molded body by vacuum forming, and the resin-integrated fiber sheet is A One-way continuous fibers in which continuous fiber groups are opened and arranged in parallel in one direction, B Cross-linked fibers in the direction of intersecting with the unidirectional continuous fibers, C. It is characterized by containing a thermoplastic resin that exists on at least the surface of the unidirectional continuous fiber and integrates the unidirectional continuous fiber and the crosslinked fiber.
  • the fiber-reinforced resin molded product of the present invention is a molded product obtained by laminating two or more of the resin-integrated fiber sheets and vacuum forming.
  • the method for producing a fiber-reinforced resin molded body of the present invention is a method for vacuum-forming the resin-integrated fiber sheet to produce a fiber-reinforced resin molded body, and the resin-integrated fiber sheet is manufactured from a lower mold having a vacuum line. Is vacuum-formed and air-pressed from the upper die.
  • the resin-integrated fiber sheet of the present invention comprises (A) unidirectional continuous fibers in which continuous fiber groups are opened and arranged in parallel in one direction, and (B) crosslinked fibers in a direction in which the continuous fibers intersect with the unidirectional continuous fibers. And (C) the thermoplastic resin present on at least the surface of the unidirectional continuous fiber and integrating the unidirectional continuous fiber and the crosslinked fiber, thereby producing the thermoplastic resin by vacuum forming.
  • the method for producing a fiber-reinforced resin molded product of the present invention has a fast molding cycle and can obtain a high-quality molded product in a short time.
  • FIG. 1 is a schematic perspective view of a resin-integrated carbon fiber sheet according to an embodiment of the present invention.
  • FIG. 2 is a schematic cross-sectional view of the resin-integrated carbon fiber sheet in the width direction.
  • FIG. 3 is a schematic process diagram showing a method for manufacturing the resin-integrated carbon fiber sheet.
  • FIG. 4 is a schematic cross-sectional view of the vacuum compressed air forming apparatus.
  • 5A-D are schematic process diagrams showing the molding method, FIG. 5A is a preparation step, FIG. 5B is a heating and heating step, FIG. 5C is a heated vacuum compressed air molding step, and FIG. 5D is a cooling and demolding step. Shown.
  • FIG. 6 is a graph showing the process operation.
  • FIG. 7 is a schematic explanatory view showing a sample cutting direction according to an embodiment of the present invention.
  • the main component of the fiber of the resin-integrated fiber sheet for vacuum forming of the present invention is a unidirectional continuous fiber that has been opened and arranged in parallel in one direction.
  • the subcomponent of the fiber is a crosslinked fiber arranged in the direction of intersecting with the unidirectional continuous fiber.
  • the main component is preferably 75 to 99% by mass, and the sub-component is preferably 1 to 25% by mass, assuming that the fiber is 100% by mass.
  • the thermoplastic resin is powdered and adhered from above the unidirectional continuous fiber and the crosslinked fiber, and is heat-sealed at least on the surface of the unidirectional continuous fiber, and the unidirectional continuous fiber and the crosslinked fiber are integrated. In this sheet, since the unidirectional continuous fiber and the crosslinked fiber are integrated by the heat-sealed thermoplastic resin, the handleability is good, and the operability at the time of laminating and vacuum forming is good.
  • the resin-integrated fiber sheet is preferably a semipreg in which a thermoplastic powder resin serving as a matrix is attached to the surfaces of unidirectional continuous fibers and crosslinked fibers and heat-sealed.
  • the thermoplastic resin on the surface penetrates and diffuses uniformly in the resin-integrated fiber sheet and between the resin-integrated fiber sheets by vacuum forming. As a result, a molded product having excellent shapeability (moldability) and not causing voids can be obtained.
  • the unidirectional continuous fiber is preferably 75 to 99% by mass, more preferably 80 to 97% by mass, and further preferably 85 to 95% by mass. ..
  • the crosslinked fiber is preferably 1 to 25% by mass, more preferably 3 to 20% by mass, and further preferably 5 to 15% by mass.
  • the resin-integrated fiber sheet has high integrity of unidirectional continuous fibers and high tensile strength in the width direction.
  • the fiber volume (Vf) of the resin-integrated fiber sheet is preferably 20 to 65% by volume and 35 to 80% by volume of the thermoplastic resin, more preferably 25 to 60% by volume of the fiber and 40 to 75% by volume of the resin.
  • the resin component of the resin-integrated fiber sheet can be directly used as the matrix resin component of the molded product. That is, it is not necessary to add a new resin when manufacturing the molded product.
  • the mass per unit area of the resin-integrated fiber sheet is preferably 10 to 3000 g / m 2 , more preferably 20 to 2000 g / m 2 , and even more preferably 30 to 1000 g / m 2 .
  • the unidirectional continuous fiber is preferably at least one selected from carbon fiber, glass fiber and high elastic modulus fiber having an elastic modulus of 380 cN / dtex or more.
  • the high elasticity fiber include aramid fiber, particularly para-aramid fiber (elasticity: 380 to 980 cN / dtex), polyallylate fiber (elasticity: 600 to 741 cN / dtex), and heterocyclic polymer (PBO, elasticity). : 1060 to 2200 cN / dtex) Fiber, high molecular weight polyethylene fiber (elasticity: 883 to 1413 cN / dtex), polyvinyl alcohol fiber (PVA, strength: 14 to 18 cN / dtex), etc. (Encyclopedia of Fibers, p. 522, March 25, 2002, Maruzen). These fibers are useful as resin reinforcing fibers. Carbon fiber is particularly useful.
  • the thickness of one of the resin-integrated fiber sheets is preferably 0.01 to 5.0 mm. Fiber sheets with a thickness in this range are easy to vacuum form. At the time of vacuum forming, two or more resin-integrated fiber sheets are laminated. The preferred number of layers is 2 to 70, more preferably 5 to 50.
  • thermoplastic resin examples include polyamide resins, polycarbonate resins, polypropylene resins, polyester resins, polyethylene resins, acrylic resins, phenoxy resins, polystyrene resins, polyimide resins, and polyether ether ketone resins. It can be used, but is not limited to these.
  • the resin adhered state of the resin-integrated fiber sheet of the present invention is that the resin is melt-solidified and adhered near the surface of the opened fiber sheet, and the resin is not impregnated inside the fiber sheet. It is preferably partially impregnated. In the above state, it is preferable to stack a plurality of resin-integrated fiber sheets and vacuum form them.
  • the width of the spread fiber sheet (hereinafter, also referred to as “spread fiber sheet”) is preferably 0.1 to 5.0 mm per 1000 constituent fibers. Specifically, the width of the spread fiber sheet is about 0.1 to 1.5 mm per 1000 constituent fibers in the case of a large tow such as 50K or 60K, and the constituent fibers in the case of a regular tow such as 12K or 15K. It is about 0.5 to 5.0 mm per 1000 pieces. Here, K means 1000 pieces. As the number of constituent fibers of the tow per fiber increases, the twist of the fibers increases and it becomes difficult to open the fibers, so that the width of the opening sheet also becomes narrower.
  • the unopened fiber tow sold by the carbon fiber manufacturer can be expanded to form an easy-to-use spread fiber sheet, which can be supplied to various molded products.
  • the carbon fiber bundle (toe) of the feed yarn is preferably 5,000 to 50,000 / bundle, and 10 to 280 carbon fiber bundles (tow) are preferably supplied.
  • a plurality of carbon fiber bundles (tow) are supplied and opened to form a single sheet in this way, the space between the carbon fiber bundle (toe) and the carbon fiber bundle (toe) is easily cleaved, but in various directions.
  • the crosslinked fibers having the property are adhered and fixed to the sheet by the resin, the cleavage between the toes can be prevented.
  • the average length of the crosslinked fibers is preferably 1 mm or more, more preferably 5 mm or more.
  • the carbon fiber sheet has high strength in the width direction and is excellent in handleability.
  • the method for producing a resin-integrated fiber sheet of the present invention includes the following steps.
  • a carbon fiber sheet will be described as a fiber sheet.
  • crosslinked fibers When the carbon fiber filament group is opened by passing through a roll or an opening bar, by applying tension to the carbon fiber filament group, crosslinked fibers can be generated from the carbon fiber filament group at the time of opening.
  • the tension of the carbon fiber filament group can be, for example, in the range of 2.5 to 30 N per 15,000 fibers.
  • air defibration it is preferable to generate crosslinked fibers by a roll or a defibration bar after this.
  • the crosslinked fibers are generated from the carbon fiber filament group, the crosslinked fibers are in a state of being interlaced with the carbon fibers constituting the carbon fiber sheet.
  • crossing includes entanglement.
  • some or all of the crosslinked fibers are present in the carbon fiber sheet and are sterically interlaced with the carbon fibers arranged in one direction.
  • a powder resin is applied to the opened carbon fiber sheet.
  • the powder resin is heated and melted in a pressure-free (no pressure) state, cooled, and the resin is partially present on at least a part of the surface of the carbon fiber sheet.
  • the crosslinked fibers are adhered and fixed to the carbon fiber sheet with the resin on the surface.
  • the fiber-reinforced resin molded product of the present invention is obtained by laminating two or more of the above-mentioned resin-integrated fiber sheets and vacuum forming.
  • the direction of the unidirectional continuous fiber may be changed. For example, it can be changed to 0 ° / 45 ° / 90 ° / 135 ° / 180 ° / ..., 0 ° / 90 ° / 180 ° / ..., and so on.
  • a molded product having the mechanical properties required for the molded product can be obtained.
  • a large sheet-like material such as an automobile bonnet, a door, a bumper, and a table top plate is suitable.
  • the resin-integrated fiber sheet is vacuum-formed from a lower mold having a vacuum line. Then, press the air pressure from the upper mold.
  • the vacuum forming is preferably vacuum pressure air forming.
  • the following method is preferable. That is, using a vacuum forming apparatus including a lower mold having a vacuum line and an upper mold having a bagging film on the lower surface, a. The process of placing two or more laminated resin-integrated fiber sheets on the lower mold and covering them with a bagging film.
  • FIG. 1 is a schematic perspective view of the resin-integrated carbon fiber sheet 1 according to the embodiment of the present invention
  • FIG. 2 is a schematic cross-sectional view of the resin-integrated carbon fiber sheet 1 in the width direction.
  • Crosslinked fibers 3 are arranged in various directions on the surface of the opened unidirectional carbon fibers 2.
  • the resin 4 is melt-solidified and adhered to the vicinity of the surface of the unidirectional carbon fiber 2, and the resin 4 is not impregnated or partially impregnated inside the unidirectional carbon fiber 2.
  • the resin 4 adheres and fixes the crosslinked fiber 3 to the surface of the unidirectional carbon fiber 2. As shown in FIG.
  • crosslinked fibers 3a and 3b are present on the surface of the unidirectional carbon fiber 2.
  • the crosslinked fibers 3a are all on the surface of the unidirectional carbon fibers 2.
  • a part of the crosslinked fiber 3b is on the surface of the unidirectional carbon fiber 2, and a part of the crosslinked fiber 3b is in a state of entering the inside and interlacing with the carbon fiber.
  • the resin 4 adheres and fixes the crosslinked fiber 3 to the surface of the unidirectional carbon fiber 2. Further, there is a portion to which the resin 4 is attached and a portion 5 to which the resin is not attached.
  • the resin 4 becomes a matrix resin of the fiber-reinforced resin molded product.
  • FIG. 3 is a schematic process diagram showing a method for producing a resin-integrated carbon fiber sheet according to an embodiment of the present invention.
  • the carbon fiber filament group (toe) 8 is pulled out from a large number of supply bobbins 7 and passed between the opening rolls 21a-21j to open the fibers (roll opening step 23).
  • Air defibration may be used instead of roll defibration.
  • the spread fiber roll may be fixed or rotated, or may vibrate in the width direction.
  • the opened tow is nipated between the nip rolls 9a and 9b, passed between a plurality of bridge rolls 12a-12b installed between the nip rolls 9a and 9b, and the tension of the toe is applied per 15,000, for example (1).
  • the bridge roll may rotate or oscillate in the width direction.
  • the bridge roll is a plurality of rolls having a satin finish, uneven surface, or a mirror surface, for example, and the carbon fiber filament group is bent, fixed, rotated, vibrated, or a combination thereof to generate crosslinked fibers.
  • 13a-13g is a guide roll.
  • the dry powder resin 15 is sprinkled on the surface of the spread sheet from the powder supply hopper 14, supplied into the heating device 16 in a pressure-free state and heated to melt the dry powder resin 15, and between the guide rolls 13e and 13 g. Cooling.
  • the dry powder resin 18 is sprinkled on the back surface of the spread fiber sheet from the powder supply hopper 17, and the dry powder resin 18 is supplied into the heating device 19 in a pressure-free state and heated to melt the dry powder resin 18, cool it, and wind up the roll 20. (Powder resin applying step 25).
  • the dry powder resins 15 and 18 are, for example, phenoxy resins (melting point 180 ° C.), the temperatures in the heating devices 16 and 19 are, for example, the melting point of the resin + 20 to 60 ° C., and the residence time is, for example, 4 seconds each.
  • the carbon fiber spread sheet has high strength in the width direction, and the constituent carbon fibers do not fall apart and can be handled as a sheet.
  • the powder resin can be applied by a powder coating method, an electrostatic coating method, a spraying method, a flow dipping method, or the like.
  • a powder coating method in which the powder resin is dropped on the surface of the carbon fiber sheet is preferable.
  • a dry powder-like powder resin is sprinkled on the opened carbon fiber sheet.
  • FIG. 4 is a schematic cross-sectional view of the vacuum compressed air forming apparatus according to the embodiment of the present invention.
  • the vacuum compressed air forming apparatus 30 has a lower mold 33 and an upper mold 39, and the lower mold 33 is fixed on the base 31 and the mold base 32, and the vacuum line 34 leads to the molding surface 35.
  • the upper mold 39 has a compressed air pipe 40, and can supply compressed air downward from the air holes 41 of the air groove 37 and the face plate 38.
  • the lower mold 33 can control heating and cooling to a predetermined temperature by a heater 42 for electromagnetic induction heating, resistance wire heating, infrared heating, etc., and a water cooling tube 43.
  • FIG. 5A-D are schematic process diagrams showing the molding method
  • FIG. 5A is a preparation step
  • FIG. 5B is a heating and heating step
  • FIG. 5C is a heated vacuum compressed air molding step
  • FIG. 5D is a cooling and demolding step. Shown.
  • FIG. 5A two or more resin-integrated fiber sheets 44 laminated on the lower mold 33 are placed, covered with a bagging film 45, and the pressure is reduced from the vacuum line 34 of the lower mold 33.
  • FIG. 5B the resin-integrated fiber sheet 44 is heated to a temperature equal to or higher than the softening point of the thermoplastic resin.
  • FIG. 5A is a preparation step
  • FIG. 5B is a heating and heating step
  • FIG. 5C is a heated vacuum compressed air molding step
  • FIG. 5D is a cooling and demolding step. Shown.
  • FIG. 5A two or more resin-integrated fiber sheets 44 laminated on the lower mold 33 are placed, covered with a bagging film 45, and
  • the resin integrated fiber sheet 44 is pressed by compressed air from the upper part of the bagging film 45 to perform vacuum pressure air forming. Finally, as shown in FIG. 5D, the molded body 46 is cooled and taken out.
  • a fluororesin film such as polytetrafluoroethylene or a heat-resistant film such as a polyimide resin film or a silicone resin film can be used.
  • FIG. 6 is a graph showing the same process operation.
  • step 1 two or more laminated resin-integrated fiber sheets 44 are placed on the lower mold and covered with the bagging film 45.
  • the pressure is reduced from the vacuum line 34 of the lower mold 33, and the temperature is raised at the same time as the pressure reduction.
  • step 3 after the temperature reaches, for example, 225 ° C., the temperature is maintained for 120 seconds, and at the same time, the resin integrated fiber sheet 44 is pressed by compressed air from the upper part of the bagging film 45 to perform vacuum pressure air molding.
  • step 4 cooling is performed while maintaining the pressure conditions, and after cooling, the molded body 46 is demolded.
  • the degree of decompression from the vacuum line 34 of the lower mold 33 is preferably 0 to 0.1 MPa, and the air pressure from the air pressure pipe 40 of the upper mold 39 is preferably 0.1 to 2.0 MPa.
  • the advantages of the present invention can be summarized as follows. (1) Unlike prepreg, since it is a semi-preg, direct molding is possible. (2) Unlike the prepreg, since it is a semi-preg, it can be molded in a high cycle, and has excellent shapeability and moldability. (3) Since the thermoplastic resin is in the form of powder and is heat-sealed, the impregnation property between fibers is good. That is, unlike a film, air bleeding is excellent at the time of molding, and voids are less likely to occur. (4) The fibers of the fiber-integrated resin sheet are continuous fibers (not short fibers) such as carbon fibers. Therefore, a thin and high-strength molded product can be obtained.
  • vacuum forming depressurization is performed by suction from the lower part, but it is preferable to pressurize by air from the upper part (vacuum pressure air forming).
  • vacuum forming is a molding method in which pressure is uniformly applied by a bagging film, a large molded body is possible.
  • vacuum forming is performed by a bagging film, it can be formed not only in a flat plate shape but also in a deep drawn three-dimensional shape.
  • the heat history for the resin can be reduced.
  • -Prepreg Long time when making a sheet + Stampable sheet making + Preheating
  • Molding-Semi-preg Short time when making a sheet + Heating only during molding As mentioned above, the semi-preg can speed up the molding time.
  • Example 1 Carbon fiber unopened fiber tow
  • the carbon fiber unopened fiber tow was manufactured by Mitsubishi Chemical Corporation, product number: PYROFILE TR 50S15L, shape: regular tow filament 15K (15,000), and a single fiber diameter of 7 ⁇ m was used.
  • An epoxy compound is attached to the carbon fibers of the unopened carbon fiber tow as a sizing agent.
  • Means for opening the unopened fiber tow The fibers were opened using the means for opening the fibers shown in FIG. In the fiber opening step, the tension of the carbon fiber filament group (toe) was set to 15 N per 15,000 fibers. In this way, an open fiber sheet having a carbon fiber filament composition of 15 K, a width of 500 mm, and a thickness of 0.08 mm was obtained.
  • the crosslinked fiber was 3.3% by mass.
  • Polypropylene and melting point: 150 to 165 ° C. (manufactured by Prime Polymer Co., Ltd.) were used as the semi-preg dry powder resin.
  • the average particle size of the dry powder resin was 80 ⁇ m.
  • An average of 27.8 g of this resin was applied to 1 m 2 of carbon fibers on one side and 55.6 g on both sides.
  • the temperatures in the heating devices 16 and 19 were 170 ° C., and the residence time was 4 seconds each.
  • the mass of the obtained resin-integrated fiber sheet was 75 g / m 2 , the fiber volume (Vf) was 45% by volume, and the thermoplastic resin was 55% by volume.
  • Step 2 The pressure was reduced at 0.1 MPa from the vacuum line of the lower mold, and the temperature was raised at the same time as the pressure was reduced.
  • Step 3 After the temperature reached 225 ° C., the temperature was maintained for 120 seconds, and at the same time, the resin-integrated fiber sheet was pressurized at 0.8 MPa from the upper part of the bagging film by compressed air to perform vacuum pressure air molding.
  • Step 4 Cooled to 60 ° C. while maintaining the pressure conditions, and after cooling, the depressurization line and the pressurization line were cut, and the molded product was demolded. One cycle of steps 1 to 4 was 400 seconds.
  • Example 2 A molded product was obtained in the same manner as in Example 1 except that the molding conditions shown in Table 1 were changed. The molding conditions are shown in Table 1.
  • a measurement sample was cut out from the molded product obtained in each example as shown in FIG. That is, six samples 52 each long along the vertical direction (arrow 51, surface fiber direction 0 °) of the molded product 50 and six samples 53 having a surface fiber direction 90 ° were cut out. Then, it was allowed to stand at 23 ° C. and a relative humidity of 50% for 48 hours or more. Then, the length, width, and thickness of each sample are measured, and the average value is shown in Table 2.
  • ⁇ Measuring instrument Surftest201 (Mitutoyo)
  • Needle material Diamond ⁇ Needle tip radius: 5 ⁇ m
  • Measuring force 4mN
  • Drive system 1 reciprocating movement (automatic retreat)
  • Drive speed 0.5 mm / sec when measuring, 1 mm / sec when reversing
  • Cutoff length 0.8mm ⁇ Standard length: 0.8 mm ⁇ Evaluation length: 4 mm ⁇ Sampling interval: 0.8 ⁇ m
  • the fiber-reinforced resin molded product of the present invention is widely applied to building materials, laptop housings, IC trays, sporting goods such as shoes and sticks, and general industrial applications such as wind turbines, automobiles, railways, ships, aerospace, and the like. it can.

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PCT/JP2020/041330 2019-11-13 2020-11-05 真空成形用樹脂一体化繊維シート、これを用いた成形体と成形体の製造方法 Ceased WO2021095626A1 (ja)

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CN202080078377.2A CN114728439B (zh) 2019-11-13 2020-11-05 真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法
JP2021556052A JP7519374B2 (ja) 2019-11-13 2020-11-05 真空成形用樹脂一体化繊維シート、これを用いた成形体と成形体の製造方法
US17/775,724 US12319047B2 (en) 2019-11-13 2020-11-05 Fiber reinforced resin molded body and method for producing the same
EP20886341.5A EP4059684A4 (en) 2019-11-13 2020-11-05 FIBER SHEET EMBEDDED WITH RESIN FOR VACUUM FORMING, AND FORMED BODY AND METHOD FOR PRODUCING FORMED BODY USING SAME

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