WO2021157652A1 - 炭素繊維強化複合材料、積層炭素繊維複合材料、積層複合材料、ワイヤレス給電器向けケースおよびワイヤレス受電器向けケース - Google Patents

炭素繊維強化複合材料、積層炭素繊維複合材料、積層複合材料、ワイヤレス給電器向けケースおよびワイヤレス受電器向けケース Download PDF

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WO2021157652A1
WO2021157652A1 PCT/JP2021/004087 JP2021004087W WO2021157652A1 WO 2021157652 A1 WO2021157652 A1 WO 2021157652A1 JP 2021004087 W JP2021004087 W JP 2021004087W WO 2021157652 A1 WO2021157652 A1 WO 2021157652A1
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Prior art keywords
carbon fiber
composite material
fiber reinforced
reinforced composite
wireless power
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PCT/JP2021/004087
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English (en)
French (fr)
Japanese (ja)
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村松秀隆
木山公志
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Toray Industries Inc
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Toray Industries Inc
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Priority to US17/795,675 priority Critical patent/US12473409B2/en
Priority to CN202180012376.2A priority patent/CN115038744B/zh
Priority to JP2021519893A priority patent/JP7793984B2/ja
Publication of WO2021157652A1 publication Critical patent/WO2021157652A1/ja
Anticipated expiration legal-status Critical
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    • 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
    • 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
    • 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
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/12—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 structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers 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
    • 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
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/212—Electromagnetic interference shielding
    • 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
    • B32B2439/00—Containers; Receptacles
    • B32B2439/40—Closed containers
    • B32B2439/62—Boxes, cartons, cases
    • 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
    • B32B2457/00—Electrical equipment
    • 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
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • 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
    • C08J2377/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
    • C08J2377/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof

Definitions

  • the present invention relates to carbon fiber reinforced composite materials, particularly those suitable for cases for wireless power feeders and cases for wireless power receivers.
  • Some gadgets such as smartphones have widespread wireless charging that can be charged without connecting to a wired cord.
  • this wireless charging method include an electromagnetic induction method and a magnetic field resonance method, which supply power from a transmitting antenna to a receiving antenna via a magnetic field, and are a case for a wireless power supply and a wireless power receiver. It is important that the material of the target case transmits a magnetic field in the frequency range used for wireless power feeding / receiving.
  • the frequency band used for this wireless charging is generally 110 kHz to 205 kHz for electronic devices such as smartphones, and commercialization is limited for electric buses and EVs, but development using 20 kHz to 250 kHz. (See, for example, Patent Document 1), magnetic field transparency in the low frequency band of 300 kHz or less is required for the case material of the wireless power supply / receiver.
  • a material having no shielding property is used in all frequency bands.
  • Typical materials include glass fiber reinforced resin materials, ceramics, glass plates, etc. These materials are composited to achieve both mechanical properties such as strength and impact resistance and cost, as well as wireless power supply devices and wireless power receiving devices. Housing has been proposed (see, for example, Patent Document 2).
  • Patent Document 2 In order to use a combination of materials, the process for bonding and joining becomes complicated, and it is difficult to reduce the cost to the level required by the market.
  • An object of the present invention is to provide a carbon fiber reinforced composite material capable of transmitting electromagnetic waves in a low frequency band while having an electromagnetic wave shielding property in a high frequency band.
  • the present inventors have completed the present invention as a result of diligent studies to solve the above problems.
  • the magnetic field shielding effect which is defined by the following equation is measured by KEC method (1), the value SE M300K (dB) in 300kHz, the ratio SE M300K / SE M1G of the value at 1 GHz SE M1G (dB) Is a carbon fiber reinforced composite material having a value of 0.50 or less.
  • SE M 20 ⁇ log 10 (H 0 / H X )... Equation (1)
  • SE M magnetic field shielding effect (dB)
  • H 0 Spatial magnetic field strength (A / m) when no test piece of carbon fiber reinforced composite material is installed
  • H X Spatial magnetic field strength (A / m) when a test piece obtained by cutting out a carbon fiber reinforced composite material to be measured into a square having a side of 150 mm is installed.
  • the present invention is a laminated carbon fiber composite material obtained by laminating at least two layers of the carbon fiber composite material of the present invention, wherein the two layers of carbon fiber composite material use a continuous fiber base material. It is a laminated carbon fiber composite material that is a combination of at least two selected from three, one using a discontinuous fiber base material and the other being injection-molded.
  • the present invention is a laminated composite material obtained by combining the carbon fiber composite material of the present invention and another resin material in the thickness direction.
  • the present invention is a case that constitutes a part of a wireless power supply, and is a case for a wireless power supply in which the carbon fiber reinforced composite material of the present invention is arranged at least in a portion that covers the power supply portion of the wireless power supply. Is.
  • the present invention is a case that constitutes a part of a wireless power receiver, and is a case for a wireless power receiver in which the carbon fiber reinforced composite material of the present invention is arranged at least in a portion that covers the power receiving portion of the wireless power supply. Is.
  • a carbon fiber reinforced composite material capable of transmitting electromagnetic waves in the low frequency band used for wireless power feeding / receiving while having electromagnetic wave shielding properties in the high frequency band, and wireless using this carbon fiber composite material. Cases for power feeders and cases for wireless power receivers can be provided.
  • FIG. 1 is a perspective view showing an example of a carbon fiber reinforced composite material according to the present invention.
  • FIG. 2 is a perspective view showing an example of a carbon fiber reinforced composite material according to the present invention.
  • FIG. 3 is a perspective view showing an example of the carbon fiber reinforced composite material according to the present invention.
  • FIG. 4 is a perspective view showing an example of the carbon fiber reinforced composite material according to the present invention.
  • FIG. 5 is a perspective view showing an example of a wireless power supply using the case for the wireless power supply according to the present invention.
  • FIG. 6 is a perspective view showing an example of a wireless power supply using the case for the wireless power supply according to the present invention.
  • 7A and 7B are (a) front side and (b) back side of a perspective view showing an example of a wireless power supply using the case for wireless power supply according to the present invention.
  • thermosetting resin or a thermoplastic resin can be preferably used.
  • the thermosetting resin may be any resin that undergoes a cross-linking reaction due to heat to form a three-dimensional cross-linked structure at least partially.
  • thermosetting resins include epoxy resins, unsaturated polyester resins, vinyl ester resins, benzoxazine resins, phenol resins, urea resins, melamine resins, thermosetting polyimide resins and the like, and modified products thereof and 2 Resins blended with more than one type can also be used.
  • the thermosetting resin may be one that is self-curing by heating, or may be one containing a curing agent, a curing accelerator, or the like.
  • epoxy resin is preferable because it has an excellent balance of mechanical properties and has a small curing shrinkage.
  • thermoplastic resin examples include polyolefin resins such as polyethylene (PE) resin and polypropylene (PP) resin, polyethylene terephthalate (PET) resin, polyamide (PA) resin, polyphenylene sulfide (PPS) resin, and the like.
  • polyolefin resins such as polyethylene (PE) resin and polypropylene (PP) resin, polyethylene terephthalate (PET) resin, polyamide (PA) resin, polyphenylene sulfide (PPS) resin, and the like.
  • PET polyethylene terephthalate
  • PA polyamide
  • PPS polyphenylene sulfide
  • thermoplastic resin examples include polymerized resins, modified resins, and alloys.
  • polypropylene-based resin is preferable from the viewpoint of lightness of the obtained molded product
  • polyamide-based resin is preferable from the viewpoint of mechanical properties and moldability
  • polyphenylene sulfide resin is preferable from the viewpoint of heat resistance.
  • Examples of the carbon fibers in the carbon fiber reinforced composite material of the present invention include polyacrylonitrile (PAN) -based, rayon-based and pitch-based carbon fibers. Among them, PAN-based carbon fibers having an excellent balance between strength and elastic modulus can be preferably used.
  • Examples of the carbon fiber form in the carbon fiber reinforced composite material of the present invention include a sheet / tape form aligned in one direction, a woven fabric form, a knitted fabric form, a non-woven fabric form, and an additive state of short fibers. can.
  • the number average fiber length L n is preferably 0.1 mm or more and 50 mm or less.
  • L n the electromagnetic wave shielding property in the high frequency band can be effectively enhanced.
  • L n the moldability of the carbon fiber reinforced composite material is improved, and it can be shaped into a complicated shape.
  • Carbon fiber reinforced composite material of the present invention is measured from the specimen of 114 sheets of 10 mm ⁇ 10 mm, the volume fraction Vf i containing fibers defined by the following formula (2), defined by the following formula (3)
  • the average value Vf ave is preferably 0.1 or more and 0.8 or less. By adjusting within this range, it is possible to obtain a material having excellent strength and elastic modulus while having an electromagnetic wave shielding property in a high frequency band.
  • Vf i (W bi / ⁇ f ) / ⁇ W bi / ⁇ f + (W ai -W bi) / ⁇ r ⁇ ... formula (2)
  • Vf ave ⁇ Vf i / n ...
  • Vf i Volume fraction of fibers contained in each test piece
  • Wai Mass (g) of each test piece before heat treatment
  • W bi Mass (g) of each test piece after heat treatment at 600 ° C. for 30 minutes.
  • ⁇ f Carbon fiber density (g / cm 3 )
  • ⁇ r Matrix resin density (g / cm 3 )
  • Vf ave Average value of fiber volume fraction
  • n Total number of test pieces (114 pieces)
  • Vf Standard deviation of the contained fiber volume fraction.
  • Vf i the value ⁇ Vf / Vf ave the standard deviation sigma Vf defined divided by Vf ave by the following formula (4) is 0.0001 to 0.5 Is preferable.
  • ⁇ Vf ( ⁇ Vf i 2 / n-Vf ave 2 ) 1/2 ...
  • Vf i Volume fraction of fibers contained in each test piece
  • Vf ave Average value of volume fraction of fibers contained n: Total number of test pieces (114 sheets)
  • ⁇ Vf Standard deviation of the volume fraction of contained fibers
  • ⁇ Vf / Vf ave is preferably 0.0001 or more. By setting ⁇ Vf / Vf ave to 0.0001 or more, it can be sufficiently achieved even with a general-purpose material, and the cost can be suppressed.
  • Carbon fiber reinforced composite material of the present invention the Vf i, it is preferable that the minimum value Vf min is 0.05 or more. By setting Vf min to 0.05 or more, it is possible to obtain a carbon fiber reinforced composite material that is stable and has excellent electromagnetic wave shielding properties in the high frequency band without locally transmitting electromagnetic waves.
  • Vf min is preferably 0.85 or less. By setting Vf min to 0.85 or less, the amount of carbon fiber used can be suppressed and the cost can be reduced.
  • the carbon fiber reinforced composite material of the present invention may be a laminate in which a plurality of thin carbon fiber reinforced composite materials are laminated.
  • the laminated structure of the carbon fiber reinforced composite material can be obtained by laminating the prepreg.
  • an orthogonal lamination method in which carbon fibers are alternately laminated in two directions orthogonal to each other can be adopted.
  • a pseudo-isotropic lamination method in which the fiber direction of a certain layer is 0 ° and the layers are laminated in the order of ⁇ 45 °, 0 °, 45 °, 90 ° can also be preferably used.
  • the carbon fiber reinforced composite material such as the woven prepreg and the carbon fiber sheet molding compound (CF-SMC) can also use the orthogonal laminating method or the pseudo isotropic laminating method as described above. ..
  • the carbon fiber reinforced composite material of the present invention is a ratio of the value SE M300K (dB) at 300 kHz and the value SE M1G (dB) at 1 GHz of the magnetic field shielding effect measured by the KEC method and defined by the following formula (1).
  • SE M300K / SE M1G is 0.50 or less.
  • SE M 20 ⁇ log 10 (H 0 / H X )... Equation (1)
  • SE M magnetic field shielding effect (dB)
  • H 0 Spatial magnetic field strength (A / m) when no test piece of carbon fiber reinforced composite material is installed
  • H X Spatial magnetic field strength (A / m) when a test piece obtained by cutting out a carbon fiber reinforced composite material to be measured into a square having a side of 150 mm is installed.
  • the magnetic field shielding effect SE M in the present invention (dB), is a physical quantity representing how the magnetic field generated from the electronic equipment and the like are what extent shielded by the carbon fiber composite material, the carbon fiber composite material The higher the number It can be said that the transmitted magnetic field is small and the magnetic field shielding property is high.
  • the KEC method standardized by the KEC Kansai Electronics Industry Promotion Center is used.
  • the magnetic field shielding property of the carbon fiber composite material increases monotonically with frequency.
  • the magnetic field shielding effect SE M300K at 300 kHz is low, it can be said that it can be sufficiently used for wireless power feeding / receiving applications in which frequency bands lower than this are used.
  • the magnetic field shielding effect SE M1G at 1 GHz is high, high frequency noise including magnetic fields and electric fields in the near field and electromagnetic waves in the distant field can be sufficiently shielded.
  • Carbon fiber reinforced composite material of the present invention it is important that the ratio SE M300K / SE M1G the SE M300K and SE M1G is 0.50 or less.
  • SE M300K / SE M1G By setting SE M300K / SE M1G to 0.50 or less, preferably 0.20 or less, more preferably 0.10 or less, the low frequency band for wireless charging can be obtained while having the electromagnetic wave shielding property of the high frequency band. It can transmit electromagnetic waves.
  • Those that satisfy this range can selectively transmit low-frequency electromagnetic waves used for wireless power feeding / receiving, and can shield high-frequency electromagnetic waves that shield high-frequency magnetic fields that cause noise, and are suitable for wireless power feeders. It can be suitably used as a constituent material of a case or a case for a wireless power receiver.
  • SE M300K / SE M1G is preferably 1.0 ⁇ 10-6 or more.
  • SE M300K / SE M1G is preferably 1.0 ⁇ 10-6 or more.
  • the SE M300k is preferably 10 dB or less. By setting the SE M300K to 10 dB or less, electromagnetic waves in the low frequency band for wireless charging can be effectively transmitted.
  • the SE M300K is preferably 1.0 ⁇ 10 -2 dB or more. By setting SE M300K to 1.0 ⁇ 10 -2 dB or more, it is possible to sufficiently achieve even general-purpose materials, and the cost can be suppressed.
  • SE M1G is preferably 20 dB or more. By setting SE M300K to 20 dB or more, high frequency noise can be effectively shielded.
  • the SE M1G is preferably 200 dB or less. By setting SE M1G to 200 dB or less, it is possible to sufficiently achieve even general-purpose materials, and the cost can be suppressed.
  • the carbon fiber reinforced composite material of the present invention is at least one selected from three, one using a continuous fiber reinforced base material, one using a discontinuous fiber reinforced base material, and one made by injection molding. Is preferable.
  • a carbon fiber reinforced composite material capable of transmitting electromagnetic waves in the low frequency band used for wireless power feeding / receiving while having electromagnetic wave shielding properties in the high frequency band is maintained in terms of mechanical properties and moldability. However, it can be obtained effectively.
  • the shape of the carbon fiber reinforced composite material of the present invention is preferably a plate shape that can efficiently cover the wireless power feeding / receiving system.
  • the plate shape include a flat plate, a corrugated plate, a hat shape, a hollow board, a cylinder, a hollow cone, a polygonal cylinder, a hollow polygonal weight, a hollow sphere, and a partial shape thereof.
  • a boss or rib structure can be added to the plate shape.
  • the carbon fiber reinforced composite material of the present invention has a different form than a plate shape, for example, a pellet shape, it can be preferably used as long as the molded product molded from the pellet shape is a plate shape.
  • FIG. 1 illustrates a perspective view of a flat plate carbon fiber reinforced composite material 1 as an example of a plate shape.
  • a flat plate is preferable because it has excellent storage efficiency during transportation.
  • FIG. 2 illustrates a perspective view of the carbon fiber reinforced composite material 2 which is a partial shape of an elliptical cylinder as an example of a plate shape. If it is a partial shape of a cylinder, it can be easily used for a molded product having a surface.
  • FIG. 3 illustrates a perspective view of the carbon fiber reinforced composite material 3 which is a partial shape of a polygonal cylinder as an example of a plate shape. This shape can efficiently cover a three-dimensional wireless power feeding / receiving system.
  • the carbon fiber reinforced composite material of the present invention preferably has a 10-point average thickness t of the thinnest portion of 0.1 mm or more and 10 mm or less.
  • t the electromagnetic wave shielding property in the high frequency band is excellent.
  • t the weight is excellent and the material cost can be further suppressed.
  • the thinnest part can be arbitrarily selected.
  • the carbon fiber reinforced composite material 4 which is a ribbed flat plate as shown in FIG. 4 the 10-point average thickness t of the thinnest portion is measured not by the rib 5 but by the flat plate portion 6.
  • the thinnest part has a 10-point average thickness t (mm) to the 1/2 power, an average value of the carbon fiber volume content Vf ave to the 1/2 power, and carbon.
  • the average fiber length L (mm) to the 1 / 4th power and the product of carbon fiber specific gravity ⁇ (g / mm 3 ) ⁇ (Vf ave ) 1/2 L 1/4 t 1/2 is 0.4 ⁇ It is preferably 10 -3 (g / mm 9/4 ) or more.
  • SE M300K / SE M1G can be effectively 0.50. It can be as follows.
  • ⁇ (Vf ave ) 1/2 L 1/4 t 1/2 is preferably 10 ⁇ 10 -3 (g / mm 9/4 ) or less.
  • ⁇ (Vf ave ) 1/2 L 1/4 t 1/2 is preferably 10 ⁇ 10 -3 (g / mm 9/4 ) or less.
  • a prepreg is a continuous fiber substrate, thermoplastic UD (U ni D irectional) tape, thermoplastic stampable sheet is discontinuous fiber substrate, CF-SMC , Injection molding materials, etc., can be selected from required specifications such as material properties and moldability.
  • a prepreg can be easily created by arranging fiber bundles or laying a fiber cloth in a flat plate mold, and then impregnating it with a thermosetting resin and pressing it. can do.
  • thermoplastic prepreg is not particularly limited, and the thermoplastic prepreg can be easily produced in the same manner as the above prepreg except that the thermoplastic resin is used instead of the thermosetting resin.
  • thermoplastic UD tape is not particularly limited, but the thermoplastic UD tape can be easily prepared in the same manner as the above-mentioned one-way prepreg except that the thermoplastic resin is used instead of the thermosetting resin. be able to.
  • a discontinuous carbon fiber base material obtained by impregnating a non-woven fabric obtained by depositing discontinuous fiber carbon fibers with a resin can be used.
  • the non-woven fabric according to the present invention is not particularly limited, and chopped fibers mechanically cut to a predetermined fiber length are produced by various mat manufacturing methods.
  • a general method such as a carding method, an airlaid method, or a wet papermaking method can be used.
  • thermosetting resins and thermoplastic resins can be used as in the case of prepreg and thermoplastic UD tape.
  • An injection molding material can be used as the carbon fiber reinforced composite material of the present invention.
  • One form of the injection molding material is obtained by kneading a desired amount of thermoplastic resin (A) and chopped yarn or continuous fiber of carbon fiber (B) in an extruder, extruding and pelletizing. Can be mentioned.
  • the fiber length in the pellet is shorter than the length in the longitudinal direction of the pellet, but the pellet in the present invention also includes long fiber pellets.
  • Such a long fiber pellet means that the fibers are arranged substantially parallel to the longitudinal direction of the pellet and the fiber length in the pellet is equal to or longer than the pellet length, as shown in Japanese Patent Publication No. 63-37694. Refers to something.
  • the resin may be impregnated in the fiber bundle or coated in the fiber bundle.
  • the fiber bundle may be pre-impregnated with a resin having the same viscosity as the coated resin or having a lower viscosity (or lower molecular weight) than the coated resin.
  • the carbon fiber length in the molded product is longer than the pellet in which the fiber length in the pellet is shorter than the length in the longitudinal direction of the pellet, so that the mechanical properties are excellent. , More preferably used.
  • thermoplastic resins can be used as in the case of the thermoplastic UD tape.
  • the carbon fiber reinforced composite material of the present invention is not particularly limited, and a molded product can be obtained by various molding methods. For example, autoclave molding, oven heating molding, press molding and injection molding and the like can be mentioned.
  • the laminated carbon fiber composite material of the present invention is made by laminating at least two layers of carbon fiber composite material and using a continuous fiber base material, a material using a discontinuous fiber base material, or injection molding. It is a combination of at least two selected from the three.
  • Examples of the laminated carbon fiber composite material include a UD hybrid material in which a thermoplastic UD tape and an injection molding material are combined, and a hybrid material composed of CF-SMC and a prepreg, and the required high frequency shielding property can be exemplified.
  • Various combinations can be selected in consideration of mechanical properties, moldability, and the like.
  • the manufacturing method for molding the molded product made of the laminated carbon fiber reinforced composite material and the method for molding the prepared laminated carbon fiber reinforced composite material and the two types of carbon fiber reinforced composite materials are used, respectively.
  • Examples thereof include a method of individually molding and bonding or joining to integrate, a method of performing molding and integration at the same time such as insert molding.
  • the laminated composite material of the present invention is a combination of the carbon fiber reinforced composite material of the present invention and another resin material in the thickness direction.
  • At least one selected from a glass fiber reinforced resin material, an organic fiber reinforced resin material, and a filler reinforced resin material can be preferably used.
  • thermoplastic prepreg As a specific example of the combination of lamination in the laminated composite material of the present invention, a laminated material in which a thermoplastic prepreg and a glass fiber reinforced resin material are combined is exemplified.
  • thermoplastic prepreg By adding the thermoplastic prepreg, it is possible to impart electromagnetic wave shielding properties in the high frequency band while maintaining the transparency of the glass fiber reinforced resin material in the low frequency band, and also to improve the mechanical properties.
  • the UD tape can be preferably used as the continuous fiber base material of the carbon fiber.
  • thermosetting resin materials include prepreg and glass prepreg, prepreg and glass SMC, CF-SMC and glass prepreg, CF-SMC and glass SMC, and the like.
  • thermoplastic resin materials include a thermoplastic prepreg and a glass tempered resin, an injection molding resin and a glass tempered resin, and the like. Further, a combination of a thermoplastic system and a thermosetting system is also exemplified.
  • organic fiber for example, natural fiber, aramid fiber, polyester fiber, LCP fiber, "Kevlar” fiber, and Zylon fiber can be used.
  • filler for example, carbon black, calcium carbonate, talc, mica and the like can be used.
  • the carbon fiber reinforced composite material of the present invention can be suitably used for a portion of the case for a wireless power supply that covers at least the power supply portion, or a portion of the case for a wireless power receiver that covers at least the power receiving portion.
  • the case for a wireless power supply of the present invention is a case that constitutes a part of the wireless power supply, and the carbon fiber reinforced composite material of the present invention is arranged at least in a portion that covers the power supply portion of the wireless power supply. It becomes.
  • the case for a wireless power receiver of the present invention is a case that constitutes a part of the wireless power receiver, and the carbon fiber reinforced composite material of the present invention is arranged at least in a portion that covers the power receiving portion of the wireless power supply. It becomes.
  • the case for a wireless power supply and the case for a wireless power receiver of the present invention transmit a magnetic field in the frequency range used for wireless power supply / power reception by molding and using the carbon fiber reinforced composite material of the present invention, and the high frequency range. In addition to shielding the noise of, it can absorb the impact from the outside and satisfy the required characteristics of being lightweight.
  • the carbon fiber reinforced composite material of the present invention is arranged at least in the portion directly above the coil of the power supply portion of the wireless power supply, and in the case for the wireless power supply of the present invention, at least wireless.
  • FIG. 5 shows an example of a wireless power supply 7 for gadgets.
  • the power feeding coil 9 is housed in the main body 8 and is covered with a top plate 10.
  • the entire surface of the top plate 10 is made of a carbon fiber reinforced composite material, and a gadget such as a smartphone can be placed on top to charge the top plate 10.
  • FIG. 6 shows an example of the wireless power supply 11 for gadgets.
  • the main body 12 and the power feeding coil 13 have the same configuration as in FIG. 4, but the top plate is composed of an outer peripheral portion 14 made of aluminum that shields power transmission and a central portion 15 made of carbon fiber reinforced composite material that does not interfere with power transmission. NS.
  • the carbon fiber reinforced composite material of the present invention is arranged at least in the power feeding portion, but when a single material is desired for simplification of the manufacturing process or the like, wireless
  • the carbon fiber reinforced composite material of the present invention can also be used for the entire case for the power feeder.
  • Devices with wireless power receivers include, for example, gadgets such as smartphones, wifi routers, digital cameras, wearable terminals, personal computers and tablet terminals, electric tools, lighting equipment, compressors, general industrial equipment such as vacuum cleaners, electric vehicles, and electric appliances. Mobility of buses, electric bikes, bicycles with electric assist, robots, electric heavy machinery, etc., electric toothbrushes, electric shaving, heart rate monitors, electrocardiographs, healthcare devices such as life log tools, etc. can be mentioned.
  • a device having a wireless power receiver If it is a small device such as a gadget such as a smartphone, it is also preferable that the case for the wireless power supply also serves as a housing for the device having the wireless power receiver.
  • Examples of the wireless power supply according to the present invention include a wireless power supply for charging the above-mentioned equipment.
  • FIG. 7 shows an example of a smartphone 16 that supports wireless charging.
  • the case of the smartphone 16 is composed of three parts, a frame 18, a screen 19, and a back panel 20, and a power receiving coil 17 is housed inside the case.
  • the back panel 20 in contact with the top plate of the wireless power supply is made of a carbon fiber reinforced composite material.
  • SE M 20 ⁇ log 10 (H 0 / H X )... Equation (1)
  • SE M magnetic field shielding effect (dB)
  • H 0 Spatial magnetic field strength (A / m) when no test piece of carbon fiber reinforced composite material is installed
  • H X Spatial magnetic field strength (A / m) when a test piece of carbon fiber reinforced composite material is installed.
  • Vf i (W bi / ⁇ f ) / ⁇ W bi / ⁇ f + (W ai -W bi) / ⁇ r ⁇ ... formula (2)
  • Vf ave ⁇ Vf i / n ... Equation (3)
  • ⁇ Vf ( ⁇ Vf i 2 / n-Vf ave 2 ) 1/2 ... Equation (4)
  • Vf i Volume fraction of fibers contained in each test piece
  • Wai Mass (g) of each test piece before heat treatment
  • W bi Mass (g) of each test piece after heat treatment at 600 ° C. for 30 minutes.
  • ⁇ f Carbon fiber density (g / cm 3 )
  • ⁇ r Matrix resin density (g / cm 3 )
  • Vf ave Average value of fiber volume fraction
  • n Total number of test pieces (114 pieces)
  • Vf Standard deviation of the contained fiber volume fraction.
  • L n ⁇ L i / n
  • L n Number average fiber length (mm)
  • n Number of fibers (400 fibers).
  • Polyamide 6 film (C)] ⁇ C-1 A predetermined amount of polyamide 6 resin (B-1) is placed on a stainless steel plate, a spacer having a predetermined thickness is placed around the spacer, and another stainless steel plate is sandwiched between the spacers. Layered with. Pressing was performed at a temperature of 250 ° C. and a pressure of 1 MPa for 5 minutes to obtain a polyamide 6 film (C-1).
  • stampable sheet By spraying chopped yarn obtained by cutting carbon fiber A-1 to a fiber length of 12.5 mm with a rotary cutter so as to be uniformly dispersed, the fiber orientation is anisotropic. A continuous carbon fiber mat was obtained.
  • a laminate of a discontinuous carbon fiber mat and a polyamide 6 film B-1 adjusted to have a thickness of 2 mm and a carbon fiber volume content of 35%, was preheated to a temperature equal to or higher than the melting temperature of the thermoplastic resin. Placed in a flat plate mold cavity, the mold is closed, a pressure of 3 MPa is applied and held for 180 seconds, and then the cavity temperature is cooled to 50 ° C. while holding the pressure to form a discontinuous carbon fiber base material.
  • a stampable sheet D-3 impregnated with a thermoplastic resin was obtained. At this time, the thickness of the stampable sheet was adjusted by using a spacer having a thickness of 2 mm.
  • stampable sheet Carbon fiber A-1 is widened to a width of 25 mm with a vibrating rod vibrating at 10 Hz, slit at 5 mm intervals using a disk-shaped split blade, and then the fiber length is 12
  • a stampable sheet D-4 was obtained in the same manner as D-3 except that it was cut to 5.5 mm.
  • Vf ave of D-5 is 0.22, Vf ave is 0.14 D-6, Vf ave of D-7 0.04) so that the carbon fiber a-1 and the polyamide 6 Resin B-1 is kneaded, and while degassing from the downstream vacuum vent, the molten resin is discharged from the die port, the obtained strand is cooled, and then cut with a cutter to shorten the carbon fiber reinforced composite material. Fiber pellets D-5 to D-7 were obtained.
  • stampable sheet D-8 Stampable sheet Same as D-4 except that the carbon fiber A-1 was cut to a fiber length of 1 mm, the thickness was 0.5 mm, and the carbon fiber volume content was adjusted to 20%. , Stampable sheet D-8 was obtained.
  • stampable sheet D-9 Same as D-4 except that the carbon fiber A-1 was cut to a fiber length of 1 mm, the thickness was 0.4 mm, and the carbon fiber volume content was adjusted to 12%. , Stampable sheet D-9 was obtained.
  • Thermoplastic UD tape Carbon fiber A-1 was prepared, and the carbon fiber bundle was continuously fed out through the thread guide. The continuously fed carbon fiber bundle was impregnated with the polyamide 6 resin B-1 in the impregnated die by supplying a fixed amount from the filled feeder. Subsequently, the carbon fiber bundle impregnated with the polyamide 6 resin B-1 was continuously drawn from the nozzle of the impregnated die using a take-up roll, passed through the cooling roll, and the polyamide 6 resin B-1 was cooled and solidified. It was wound on a winder as a thermoplastic UD tape. The thickness of the obtained thermoplastic UD tape was 0.3 mm, and the carbon fiber directions were arranged in one direction. The volume fraction of fibers contained in the thermoplastic UD tape was 50 vol%.
  • Example 1 The carbon fiber reinforced composite material D-1 is cut into predetermined dimensions in the carbon fiber orientation direction (0 ° direction) and in the direction shifted 45 degrees to the right from the carbon fiber orientation direction (45 ° direction).
  • the laminate was exposed to a cured atmosphere to obtain a molded plate in which the matrix resin was cured, and was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours before being evaluated. ..
  • Table 1 The results are shown in Table 1.
  • Example 2 A molded plate was obtained and used for evaluation in the same manner as in Example 1 except that the carbon fiber reinforced composite material D-2 was used. The results are shown in Table 1.
  • Example 3 Molded plates were obtained and used for evaluation in the same manner as in Example 1 except that the lamination mode was 48 layers pseudo-isotropic ([ ⁇ 45 / 0 / + 45/90] 6S). The results are shown in Table 1.
  • Example 4 The carbon fiber reinforced composite material D-3 was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 2.
  • Example 5 The carbon fiber reinforced composite material D-4 was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 2.
  • Carbon fiber reinforced composite materials D-5 to D-7 are molded using an injection molding machine (SE75DUZ-C250 type manufactured by Sumitomo Heavy Industries, Ltd.) under the conditions of a cylinder temperature of 300 ° C and a mold temperature of 80 ° C. Molded into. The obtained test piece was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are summarized in Table 3.
  • Example 9 The carbon fiber reinforced composite material D-8 was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 4.
  • Example 10 The carbon fiber reinforced composite material D-9 was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 4.
  • Example 11 The carbon fiber reinforced composite material D-10 was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 5.
  • Example 12 After arranging the carbon fiber reinforced composite material D-10 having a thickness of 0.3 mm on the entire surface of the injection molding die for a flat plate having a thickness of 3 mm, the glass fiber reinforced resin material E-2 was injection molded to have a thickness of 3 mm. A laminated material was obtained. The obtained laminated board was allowed to stand in a constant temperature and humidity chamber adjusted to a temperature of 23 ° C. and 50% RH for 24 hours, and then subjected to evaluation. The results are shown in Table 5.
  • both SE M300K / SE M1G are 0.50 or less, and it is possible to shield the high frequency that becomes a noise source while transmitting the low frequency used for wireless charging.
  • carbon fiber reinforced composite materials of Examples 1 to 7, 9 to 12 were particularly excellent in the efficiency of wireless charging.
  • Example 8 was superior in wireless charging efficiency as compared with Comparative Example 1, although it was not as good as Examples 1 to 7, 9 to 12.
  • Comparative Example 1 was inferior in wireless charging efficiency.
  • the carbon fiber reinforced composite material of the present invention is suitable for wireless power feeders / receivers because it can shield high frequencies that are noise sources while transmitting low frequencies used for wireless charging among the shielding characteristics in near magnetic fields. It can be suitably used for a case.

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PCT/JP2021/004087 2020-02-06 2021-02-04 炭素繊維強化複合材料、積層炭素繊維複合材料、積層複合材料、ワイヤレス給電器向けケースおよびワイヤレス受電器向けケース Ceased WO2021157652A1 (ja)

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US17/795,675 US12473409B2 (en) 2020-02-06 2021-02-04 Carbon fiber-reinforced composite material, stacked carbon fiber composite material, stacked composite material, case for wireless power supplying device, and case for wireless power receiving device
CN202180012376.2A CN115038744B (zh) 2020-02-06 2021-02-04 碳纤维增强复合材料、层叠碳纤维复合材料、层叠复合材料、用于无线供电器的壳体和用于无线受电器的壳体
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