WO2021157424A1 - プリフォーム - Google Patents

プリフォーム Download PDF

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Publication number
WO2021157424A1
WO2021157424A1 PCT/JP2021/002597 JP2021002597W WO2021157424A1 WO 2021157424 A1 WO2021157424 A1 WO 2021157424A1 JP 2021002597 W JP2021002597 W JP 2021002597W WO 2021157424 A1 WO2021157424 A1 WO 2021157424A1
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WO
WIPO (PCT)
Prior art keywords
reinforcing fiber
fiber sheet
cut
preform
reinforcing
Prior art date
Application number
PCT/JP2021/002597
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English (en)
French (fr)
Japanese (ja)
Inventor
津村祐介
三辻祐樹
細川直史
Original Assignee
東レ株式会社
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.)
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Application filed by 東レ株式会社 filed Critical 東レ株式会社
Priority to JP2021504549A priority Critical patent/JPWO2021157424A1/ja
Publication of WO2021157424A1 publication Critical patent/WO2021157424A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • 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
    • 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
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • 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
    • 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
    • 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
    • B32B5/28—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 impregnated with or embedded in a plastic substance
    • 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

Definitions

  • the present invention relates to a preform of a reinforcing fiber sheet that can be used for compression molding such as press molding. More specifically, the present invention can be suitably used for automobile structural materials, aircraft members, sports equipment, etc., which are easy to manufacture fiber reinforced resin molded products and have excellent material yield of reinforced fiber sheets. It relates to the preform of the reinforcing fiber sheet.
  • fiber reinforced plastic is lightweight, high strength, and high rigidity, it is used in a wide range of fields such as sports / leisure applications such as fishing rods and golf shafts, and industrial applications such as automobiles and aircraft.
  • a method of using a reinforcing fiber sheet is known for producing a fiber reinforced resin.
  • a prepreg which is an intermediate material in which a fiber reinforcing material made of long fibers such as reinforcing fibers is impregnated with a resin is used. The method used is preferably used.
  • a molded product made of a fiber reinforced resin can be obtained by cutting the prepreg into a desired shape according to the shape of the molded product, laminating and shaping the prepreg, and heat-curing the prepreg in a mold (for example, Patent Document 1).
  • Patent Document 2 describes a method of arranging and press-molding.
  • Patent Document 3 An optical film chip intermediate that is excellent in chamfering efficiency and workability for optical film chips used in liquid crystal display devices and the like is described.
  • a reinforcing fiber sheet such as a prepreg is cut into a desired shape, laminated and shaped to form a preform, and then compression-molded in a mold. Even if the fiber sheet is efficiently cut into the shape of a molded product, there is a problem that not a little scrap material is generated and the material yield is lowered. This is also pointed out in Patent Document 2 that even if the reinforcing fiber sheet is efficiently cut into the shape of a molded product, not a little scrap material is generated. Further, when cutting into the shape of a molded product, the shape may be complicated and it may take time to cut.
  • Patent Document 3 when the method described in Patent Document 3 is applied to a reinforcing fiber base material and cut into a trapezoid, even if the material yield is improved, the applicable molded product shape is limited to the trapezoid and is versatile. There was an inferior problem. Further, when this shape is used for a molded product having a different shape having a curved contour, for example, the reinforcing fiber may not reach the end of the molded product and may be unfilled, or a resin-rich region may be formed. Mechanical characteristics and design may deteriorate.
  • an object of the present invention is to pay attention to the above-mentioned problems and to provide a preform of a reinforcing fiber sheet which has good mechanical properties and is effective for improving the material yield.
  • the present invention for solving the above problems has any of the following configurations.
  • the number of vertices is 5 or more, and at least one or more internal angles are larger than 180 degrees.
  • B One or more sides are curves.
  • a preform obtained by laminating two or more reinforcing fiber sheet cut bodies cut from a reinforcing fiber sheet, and the reinforcing fiber sheet cut body has a shape satisfying at least one of the following (a) and (b).
  • the number of vertices is 5 or more, and at least one or more internal angles are larger than 180 degrees.
  • One or more sides are curves.
  • the preform according to the present invention it can be easily produced in a short time, and it is possible to improve the material yield while exhibiting excellent mechanical properties.
  • FIG. 1 It is a figure which shows an example of the reinforcing fiber sheet used in this invention, and the reinforcing fiber sheet cut body having a predetermined shape used in this invention cut from a reinforcing fiber sheet. It is a figure which shows the state which the number of vertices used in this invention is 5 or more, and at least one or more inner angle is larger than 180 degrees, and the reinforced fiber sheet cut body is arranged in a plane without a gap. It is a schematic diagram which shows the state which the reinforcing fiber sheet cut body which one side or more is curved, which is used in this invention, is arranged in a plane without a gap.
  • the preform of the present invention is a preform in which two or more reinforcing fiber sheet cut bodies having a predetermined shape, cut from a reinforcing fiber sheet, are laminated, which is used when manufacturing a molded product in this way, and is a reinforcing fiber.
  • the sheet cut body is a preform characterized by satisfying at least one of the following (a) and (b) and having a tessellation property of being arranged without gaps in the plane of the reinforcing fiber sheet.
  • the "side” has a broad concept including not only a line segment connecting the vertices of a polygon but also a curve connecting the vertices of a closed curve.
  • the number of vertices is 5 or more, and at least one or more internal angles are larger than 180 degrees.
  • One or more sides are curves.
  • the reinforcing fiber sheet used in the present invention can be preferably used regardless of whether it is a reinforcing fiber sheet composed of only reinforcing fibers or a reinforcing fiber sheet composed of reinforcing fibers and a resin.
  • a wide sheet-like material as shown in FIG. 1 or a narrow tape-like material can be mentioned as a preferable example.
  • reinforcing fiber constituting the reinforcing fiber sheet for example, continuous fiber can be used.
  • a preform made of a reinforcing fiber sheet in which reinforcing fibers are continuous fibers can be exemplified as a configuration having high strength because it is easy to utilize the strength of the fibers when the molded product is exposed to a load. Further, in the reinforcing fiber sheet made into continuous fibers, a unidirectional reinforcing fiber sheet in which the continuous fibers are arranged in the same direction, a woven reinforcing fiber sheet in which the continuous fibers are woven, and continuous fibers are oriented in a plurality of directions. It can be exemplified as a multi-axis base material typified by non-crimp fabric (NCF), a braiding base material in which continuous fibers are woven, and a structure in which these are impregnated with a resin.
  • NCF non-crimp fabric
  • the volume content of the reinforcing fiber is preferably 40% or more and less than 80%, more preferably 45% or more and less than 75%, and further preferably 50. % Or more and less than 70%.
  • the cut prepreg is excellent in filling efficiency of the reinforcing fibers, and is therefore suitable for drawing out the reinforcing effect of the reinforcing fibers, and is effective in improving the rigidity of the molded product.
  • the amount of reinforcing fibers contained in the reinforcing fiber sheet is preferably a basis weight of reinforcing fibers in the case of the sheet material is less than 50 g / m 2 or more 1000 g / m 2.
  • a basis weight of reinforcing fibers in the case of the sheet material is less than 50 g / m 2 or more 1000 g / m 2.
  • the basis weight is more preferably 100 g / m 2 or more and less than 600 g / m 2 , and further preferably 150 g / m 2 or more and less than 400 g / m 2 in order to achieve both structural uniformity and heat transfer uniformity. be.
  • To measure the basis weight of the reinforcing fiber a region of 10 cm square is cut out from the sheet-like material of the reinforcing fiber, the mass thereof is measured, and the weight of the region is divided by the area to derive the basis weight of the region. This measurement is performed 10 times for different regions of the sheet-like material of the reinforcing fibers, and the average value is adopted as the basis weight of the reinforcing fibers.
  • a reinforcing fiber sheet containing a portion where the resin is not impregnated with the reinforcing fiber can also be used.
  • the unimpregnated portion is a portion where the resin does not adhere to one or both of the surface and the inside of the reinforcing fiber.
  • the resin-unimpregnated portion of the reinforcing fiber sheet is impregnated with the resin that has flowed from other portions by undergoing compression molding such as press molding, and can exhibit desired characteristics as a healthy portion.
  • discontinuous fibers can be used as the reinforcing fibers constituting the reinforcing fiber sheet. Since the preform made of the reinforcing fiber sheet in which the reinforcing fiber is a discontinuous fiber is excellent in filling property into a shape, it can be exemplified as a configuration for preventing deterioration of mechanical properties due to an unfilled portion or a resin rich. As the reinforcing fiber sheet in which the reinforcing fiber is a discontinuous fiber, a mat or a sheet mold compound (SMC) sprayed with chopped strands can be exemplified.
  • SMC sheet mold compound
  • the reinforcing fiber used in the reinforcing fiber sheet for example, carbon fiber, glass fiber, aramid fiber, alumina fiber, silicon carbide fiber, boron fiber, metal fiber, natural fiber, mineral fiber and the like can be used, and these can be used. Can be used alone or in combination of two or more. Among them, carbon fibers such as PAN-based, pitch-based and rayon-based are preferably used from the viewpoint of high specific strength and specific rigidity and weight reduction effect. Further, from the viewpoint of increasing the conductivity of the obtained molded product, reinforcing fibers coated with a metal such as nickel, copper or ytterbium can also be used.
  • a metal such as nickel, copper or ytterbium
  • thermosetting resins such as unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol resin, urea melamine resin, maleimide resin and polyimide resin, and copolymers thereof. , Modified products, and resins blended with at least two of these.
  • epoxy resins are preferably used from the viewpoint of the mechanical properties of the obtained molded product.
  • the glass transition temperature of the thermosetting resin used in the uncured state is preferably 80 ° C. or lower, more preferably 70 ° C. or lower, and further preferably 60 ° C. It is below ° C.
  • thermoplastic resin such as a polyamide resin or a polyphenylene sulfide resin
  • the reinforcing fiber sheet cut body used in the present invention is a sheet-shaped reinforcing fiber sheet cut into a predetermined shape, or a sheet-shaped reinforcing fiber sheet cut into a tape shape and then arranged in a predetermined shape. , Or a tape-shaped reinforcing fiber sheet that has been cut and arranged in a predetermined shape. Further, a reinforcing fiber sheet cut body cut into a desired shape after laminating a plurality of layers of the sheet-shaped reinforcing fiber sheet shown in FIG. 1 can also be used. When laminating in a plurality of layers, at least one reinforcing fiber sheet is laminated in different fiber directions to be reinforced as a fiber reinforced resin in a plurality of directions, and thus exhibits preferable mechanical properties.
  • the reinforcing fiber sheet cut body used in the preform of the present invention has a tessellation property that one type can be arranged on a flat surface without gaps, or two types have a tessellation property that can be arranged on a flat surface without gaps.
  • the tessellation is a property that allows a finite number of types of plane figures to be arranged without gaps in the plane.
  • the surplus portion that has been conventionally discarded can be reduced, and the material yield can be improved.
  • the contour of one reinforcing fiber sheet cut body can be cut so as to overlap the contour of another cut body, by cutting the contour of one reinforcing fiber sheet cut body, another reinforcing fiber sheet in contact with the contour can be cut.
  • the contour of the cut body can be cut at the same time. That is, the cutting time of the reinforcing fiber sheet cut body can be reduced.
  • the reinforcing fiber sheet cut body used in the preform of the present invention further has any one or more combinations of the following.
  • the number of vertices is 5 or more, and at least one or more internal angles are larger than 180 degrees.
  • One or more sides are curves.
  • the reinforcing fiber sheet cut body used in the preform of the present invention having five or more vertices and at least one or more internal angles larger than 180 degrees is exemplified, but limited to these. It's not a thing.
  • the reinforcing fiber sheet cut body used in the preform of the present invention in which one or more sides are curved, is exemplified in FIG. 3, but is not limited thereto. With such a configuration, it is possible to increase the area of the preform while making the shape of the preform fit in the mold cavity.
  • the effect of the reinforced fiber sheet cut body when the number of vertices is 5 or more and at least one or more internal angles are larger than 180 degrees will be specifically described with reference to FIG. Examples thereof include a reinforcing fiber sheet cutting body 301 used for a conventional preform, a reinforcing fiber sheet cutting body 201 used for the preform of the present invention, and a mold cavity 401. Since the reinforcing fiber sheet cut body used in the preform of the present invention can have a larger area than the reinforcing fiber sheet cut body used in the conventional preform, the flow rate ⁇ (%) of the preform described later. Can be reduced, and the generation of unfilled portions and resin-rich regions of molded products can be suppressed.
  • the effect of making one or more sides curved will be specifically described with reference to FIG. Examples thereof include a reinforcing fiber sheet cutting body 302 used for a conventional preform, a reinforcing fiber sheet cutting body 217 used for the preform of the present invention, and a mold cavity 402. Since the reinforcing fiber sheet cut body used in the preform of the present invention has a larger area than the reinforcing fiber sheet cut body used in the conventional preform, the flow rate ⁇ (%) of the preform described later should be reduced. It is possible to suppress the generation of unfilled portions and resin-rich regions of molded products.
  • the preform of the present invention is also a preform obtained by laminating two or more reinforcing fiber sheet cut bodies having a predetermined shape, which are cut from a reinforcing fiber sheet, and the reinforcing fiber sheet cut body is a main cut body and a main cut body. It has an auxiliary cutting body in which the number of vertices is equal to or less than the number of vertices of the main cutting body, and further, the main cutting body and the auxiliary cutting body are combined and arranged in two types without a gap in the reinforcing fiber sheet plane. It has a flat filling property.
  • the material yield can be improved and the cutting time of the reinforced fiber sheet cut body can be reduced for the above-mentioned reason.
  • the main cut body used in the preform of the present invention further has any one or more combinations of the following.
  • the number of vertices is 5 or more, and at least one or more internal angles are larger than 180 degrees.
  • One or more sides are curves.
  • the flow rate ⁇ (%) of the preform is calculated by the following formula using the area Sp (cm 2 ) of the preform and the area Sc (cm 2) of the molded product.
  • ⁇ Sc / Sp ⁇ 100
  • the reinforcing fiber sheet used for press molding generally has a limit value that allows it to flow. As the flow rate ⁇ (%) of the preform increases, unfilled portions and resin-rich regions are likely to occur in the molded product. Therefore, the reinforcing fiber sheet cut body used in the preform of the present invention can have a smaller flow rate ⁇ of the preform than the reinforcing fiber sheet cut body used in the conventional preform, so that the molded product may have an unfilled portion or a molded product. It is preferable that a resin-rich region is less likely to occur.
  • the flow rate ⁇ (%) of the preform is preferably 100% or more and 300% or less. Further, the flow rate ⁇ (%) of the preform is preferably 100% or more and 200% or less in order to obtain a molded product having a good appearance while maintaining the structure of the reinforcing fibers, and further, the alignment of the reinforcing fibers is disturbed. From the viewpoint of exhibiting good mechanical properties in the molded product while suppressing the above, it is preferably 100% or more and 150% or less.
  • the main cut body and the auxiliary cut body used in the preform of the present invention are one type of reinforced fiber sheet cut body having a tessellation property, which is one type exemplified in FIGS. As shown in the above, the shape can be divided into a main cutting body 501 and an auxiliary cutting body 601.
  • the main cutting body has a shape that can be arranged so as to be adjacent to at least two other main cutting bodies when two types of main cutting bodies are arranged together with the auxiliary cutting body without a gap on a flat surface.
  • the reinforced fiber sheet cut body of the main cut body and the reinforced fiber sheet cut body of the auxiliary cut body are cut from the reinforced fiber sheet and picked up, the main cut body can be continuously picked up. Therefore, it is preferable that the reinforced fiber sheet of the main cut body is contaminated with the reinforced fiber sheet of the auxiliary cut body to the cut body, and the sorting is easy.
  • the preform of the present invention can further have at least two reinforcing fiber sheet cut pieces having predetermined shapes different from each other.
  • the number of laminated reinforced fiber sheet cut bodies and the thickness can be changed according to the location of the preform, and the degree of freedom in the laminated design is increased. Therefore, a molded product having preferable mechanical characteristics can be obtained. You can get it.
  • the preform of the present invention can further have a main cut body in which at least two reinforcing fiber sheet cut bodies are different from each other.
  • at least two reinforcing fiber sheet cutting bodies can have auxiliary cutting bodies different from each other.
  • the preform of the present invention can be a unidirectional prepreg in which the fiber reinforced sheet contains continuous fiber reinforced fibers and a thermosetting resin.
  • reinforcing fibers constituting the unidirectional prepreg continuous fibers arranged in the same direction can be used.
  • the volume content of the reinforcing fiber preferable as a unidirectional prepreg is preferably 40% or more and less than 80%, more preferably 45% or more and less than 75%, and further preferably 50% or more and less than 70%.
  • the unidirectional prepreg is suitable for drawing out the reinforcing effect of the reinforcing fiber, and is effective in improving the rigidity of the molded product.
  • a basis weight of the reinforcing fibers in the case of the sheet is preferably less than 50 g / m 2 or more 1000 g / m 2. If the basis weight is too small, pores may be formed in the plane of the unidirectional prepreg in the absence of reinforcing fibers. By setting the basis weight to be equal to or higher than the lower limit of the above preferable range, it becomes possible to eliminate pores that are weak parts in the fiber reinforced resin. Further, if the basis weight is less than the upper limit of the above preferable range, heat can be uniformly transferred to the inside in the preheating of molding.
  • the basis weight is more preferably 100 g / m 2 or more and less than 600 g / m 2 , and further preferably 150 g / m 2 or more and less than 400 g / m 2 in order to achieve both structural uniformity and heat transfer uniformity.
  • the basis weight of the reinforcing fibers is measured by cutting out a 10 cm square region from the sheet-shaped material of the reinforcing fibers, measuring the mass thereof, and dividing by the area. The measurement is performed 10 times for different parts of the sheet-like material of the reinforcing fiber, and the average value is adopted as the basis weight of the reinforcing fiber.
  • a prepreg containing a portion where the thermosetting resin is not impregnated in the reinforcing fiber can also be used.
  • the unimpregnated portion is a portion where the thermosetting resin does not adhere to the surface of the reinforcing fiber.
  • the resin-unimpregnated portion of the unidirectional prepreg is impregnated with the thermosetting resin that has flowed from another portion through compression molding such as press molding, and can exhibit desired characteristics as a healthy portion.
  • reinforcing fiber used for the unidirectional prepreg for example, carbon fiber, glass fiber, aramid fiber, alumina fiber, silicon carbide fiber, boron fiber, metal fiber, natural fiber, mineral fiber and the like can be used, and these can be used. Can be used alone or in combination of two or more. Among them, carbon fibers such as PAN-based, pitch-based and rayon-based are preferably used from the viewpoint of high specific strength and specific rigidity and weight reduction effect. Further, from the viewpoint of increasing the conductivity of the obtained molded product, reinforcing fibers coated with a metal such as nickel, copper or ytterbium can also be used.
  • a metal such as nickel, copper or ytterbium
  • thermosetting resin used for the one-way prepreg examples include unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol resin, urea-melamine resin, maleimide resin, polyimide resin and other resins, and copolymers thereof. , Modified products, and resins blended with at least two of these. Of these, epoxy resins are preferably used from the viewpoint of the mechanical properties of the obtained molded product. Further, since the unidirectional prepreg is cured in the molding step, the glass transition temperature of the thermosetting resin used in the uncured state is preferably 80 ° C. or lower, more preferably 70 ° C. or lower, and further preferably 60 ° C. It is below ° C.
  • the preform of the present invention can further be a cut prepreg in which the unidirectional prepreg has a plurality of cuts across the continuous fiber.
  • This configuration is the most preferable embodiment for improving the material yield while exhibiting good mechanical properties.
  • the cut insertion portion is likely to be opened or displaced, and the stretchability of the reinforcing fiber sheet cut body in the reinforcing fiber direction is improved.
  • the cut-and-insertion portion is opened by the flow during compression molding, and the fiber bundles of the reinforcing fibers are separated from each other, so that the cut body of the reinforcing fiber sheet exhibits flexibility and the fluidity is enhanced.
  • the cut body of the reinforcing fiber sheet By configuring the cut body of the reinforcing fiber sheet to flow in this way, the reinforcing fibers reach the end of the molded product, the area where the resin is excessive is reduced, and a molded product having excellent mechanical properties and appearance is obtained. be able to. From the viewpoint of fluidity, it is preferable that the cut is made in the entire area in the thickness direction of the unidirectional prepreg.
  • the length of the cut reinforcing fiber included in the notch insertion prepreg is preferably 3 mm or more and 100 mm or less, more preferably 5 mm or more and 75 mm or less, and further preferably 10 mm or more and 50 mm or less.
  • the molded product exhibits sufficient mechanical properties.
  • the preform can obtain sufficient fluidity at the time of molding.
  • the cut length varies depending on the cutting direction and the angle formed by the main axis direction of the reinforcing fibers of the cut prepreg, but the projected length of the reinforcing fibers in the fiber orthogonal direction is preferably 0.05 mm or more and 25 mm or less. It is more preferably 0.1 mm or more and 10 mm or less, and further preferably 0.15 mm or more and 5 mm or less.
  • the cut length is set to be equal to or greater than the lower limit of the above preferable range, the opening amount of the cut insertion portion is increased, and the components of the laminated body exhibit sufficient fluidity.
  • the cut length is set to be equal to or less than the upper limit of the above preferable range, the opening of the cut insertion portion is suppressed, and a molded product having excellent appearance quality and mechanical properties can be obtained.
  • the cut prepreg can be used for preform in combination with a reinforcing fiber sheet in which reinforcing fibers are continuous fibers.
  • molded products obtained by using the preform of the present invention include, for example, electrical and electronic equipment parts, civil engineering, building material parts, automobiles, motorcycle structural parts, and aircraft parts.
  • housings for electric and electronic devices civil engineering, panels for building materials, structural parts for automobiles, and parts for aircraft.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Textile Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
PCT/JP2021/002597 2020-02-06 2021-01-26 プリフォーム WO2021157424A1 (ja)

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JP2021504549A JPWO2021157424A1 (es) 2020-02-06 2021-01-26

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Application Number Priority Date Filing Date Title
JP2020-018749 2020-02-06
JP2020018749 2020-02-06

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WO2021157424A1 true WO2021157424A1 (ja) 2021-08-12

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WO2008099670A1 (ja) * 2007-02-02 2008-08-21 Toray Industries, Inc. プリプレグ基材、積層基材、繊維強化プラスチック、プリプレグ基材の製造方法、および、繊維強化プラスチックの製造方法
JP2008260793A (ja) * 2007-04-10 2008-10-30 Toray Ind Inc 積層基材および繊維強化プラスチック
JP2010030193A (ja) * 2008-07-30 2010-02-12 Toray Ind Inc 繊維強化プラスチックの製造方法
JP2013510013A (ja) * 2009-11-06 2013-03-21 ザ・ボーイング・カンパニー 圧縮成形法及び同成形法により成形される強化熱可塑性部品
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JPS63180208U (es) * 1987-05-15 1988-11-21
WO2008099670A1 (ja) * 2007-02-02 2008-08-21 Toray Industries, Inc. プリプレグ基材、積層基材、繊維強化プラスチック、プリプレグ基材の製造方法、および、繊維強化プラスチックの製造方法
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