WO2022185918A1 - プリフォーム構造体、繊維強化プラスチック、及びプリフォーム構造体の製造方法 - Google Patents

プリフォーム構造体、繊維強化プラスチック、及びプリフォーム構造体の製造方法 Download PDF

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Publication number
WO2022185918A1
WO2022185918A1 PCT/JP2022/006160 JP2022006160W WO2022185918A1 WO 2022185918 A1 WO2022185918 A1 WO 2022185918A1 JP 2022006160 W JP2022006160 W JP 2022006160W WO 2022185918 A1 WO2022185918 A1 WO 2022185918A1
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Prior art keywords
carbon
preform structure
support layer
resin
fiber
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PCT/JP2022/006160
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English (en)
French (fr)
Japanese (ja)
Inventor
佳明 萩原
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Lintec Corp
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Lintec Corp
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Publication date
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Priority to JP2023503697A priority Critical patent/JP7836292B2/ja
Priority to US18/279,585 priority patent/US20240309159A1/en
Priority to EP22762974.8A priority patent/EP4282628B1/en
Publication of WO2022185918A1 publication Critical patent/WO2022185918A1/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
    • C08J5/24—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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—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
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two-dimensional [2D] structure
    • 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
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three-dimensional [3D] structure
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/447—Yarns or threads for specific use in general industrial applications, e.g. as filters or reinforcement
    • 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
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0077—Yield strength; Tensile strength
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/10—Inorganic fibres based on non-oxides other than metals
    • D10B2101/12—Carbon; Pitch
    • D10B2101/122—Nanocarbons
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • the present invention relates to a preform structure, fiber-reinforced plastic, and a method for manufacturing a preform structure.
  • Fiber-reinforced plastic As a fiber-reinforced plastic, a preform structure containing reinforcing fibers such as carbon fibers or glass fibers embedded in a resin body is known. Fiber-reinforced plastics are used in various fields such as sporting goods, leisure goods, materials for automobiles, materials for aircraft, and members for electronic devices. Carbon fibers, which have particularly high strength, are used as reinforcing fibers when high strength is required. However, since carbon fiber is difficult to process into a free shape, carbon fiber cloth is used when used in a preform structure.
  • Patent Document 1 discloses a preform structure in which two or more layers in which reinforcing fiber bundles are aligned so that their longitudinal directions are arranged in one direction are laminated so that the longitudinal directions of the reinforcing fiber bundles are different. Have been described. In this preform structure, auxiliary threads are used as means for constraining the positions of the reinforcing fiber bundles.
  • An object of the present invention is to provide a preform structure containing carbon fiber and having a high degree of design freedom, a fiber-reinforced plastic, and a method for manufacturing a preform structure.
  • a preform structure comprising carbon fibers, a support layer underlying the carbon fibers, and carbon-based yarns for fastening the carbon fibers to the support layer.
  • the carbon-based yarn is preferably at least one selected from the group consisting of carbon nanotube yarn and composite yarn of resin and carbon nanotube yarn.
  • the support layer is preferably at least one selected from the group consisting of glass fiber cloth, carbon fiber cloth, resin cloth, and resin film.
  • the support layer is preferably at least one selected from the group consisting of glass fiber cloth and carbon fiber cloth.
  • the support layer is preferably at least one selected from the group consisting of resin cloth and resin film.
  • a fiber-reinforced plastic comprising the preform structure according to the aspect of the present invention and a resin impregnated in the preform structure.
  • a material for the resin cloth or the resin film comprising the preform structure according to the aspect of the present invention and a resin impregnated in the preform structure.
  • a fiber-reinforced plastic is provided in which the resin and the resin impregnated in the preform structure are made of the same material.
  • a method of manufacturing a preform structure according to the aspect of the present invention, wherein the carbon fiber is arranged on the support layer, and the carbon-based yarn is used to form the A method of manufacturing a preform structure is provided comprising the step of anchoring carbon fibers to the support layer.
  • the carbon fibers are sewn to the support layer by sewing with the carbon-based thread.
  • the tensile strength of the carbon-based yarn is 500 MPa or more.
  • a preform structure containing carbon fibers and having a high degree of design freedom a fiber-reinforced plastic, and a method for manufacturing a preform structure.
  • FIG. 1 is a schematic diagram showing a fiber-reinforced plastic according to a first embodiment of the present invention
  • the preform structure 10 As shown in FIG. 1, the preform structure 10 according to the present embodiment includes carbon fibers 2, a support layer 1 serving as a base for the carbon fibers 2, and carbon-based yarns for fixing the carbon fibers 2 to the support layer 1. 3 and .
  • the carbon fibers 2 are arranged on the support layer 1 with a free design and are fastened by the carbon-based threads 3 .
  • the carbon fibers 2 are normally used as carbon fiber cloth, in this embodiment, the carbon fibers 2 can be used in the preform structure 10 in forms other than cloth. Therefore, the degree of freedom in designing the carbon fiber 2 can be increased.
  • the support layer 1 is a carbon fiber cloth
  • a preform structure with different carbon fiber designs can be laminated.
  • the support layer 1 is a layer that serves as a base for the carbon fibers 2 .
  • Carbon fibers 2 can be arranged on the support layer 1 in a free design.
  • the support layer 1 include glass fiber cloth, carbon fiber cloth, resin cloth, and resin film.
  • glass fiber cloth and carbon fiber cloth are preferable from the viewpoint of the strength of the preform structure 10 .
  • Carbon fiber cloth is particularly preferable from the viewpoint that the entire preform structure 10 can be made of a carbon-based material.
  • the support layer 1 is glass fiber cloth or carbon fiber cloth, for example, as shown in FIG. With such a cloth, the carbon-based yarn 3 can be passed through the weave of the cloth, and the carbon-based yarn 3 can fasten the carbon fiber 2 .
  • the carbon fiber 2 is a fiber in which 90% or more by mass is composed of carbon, which is obtained by thermally carbonizing a precursor of organic fiber.
  • the carbon fiber 2 can be produced by carbonizing acrylic fiber or pitch (a by-product of petroleum, coal, coal tar, etc.) as a raw material at a high temperature.
  • Examples of the carbon fiber 2 include PAN-based carbon fiber (carbon fiber using acrylic fiber) and pitch-based carbon fiber (carbon fiber using pitch).
  • the carbon-based yarn 3 is a yarn that can penetrate the support layer 1 and contains fibers made of a carbon-based material. Note that the carbon-based yarn 3 does not include the carbon fiber 2 described above. The carbon fiber 2 lacks flexibility and cannot be sewn like thread. On the other hand, the carbon-based thread 3 can be passed through a weave of carbon fiber cloth or the like, and the carbon-based thread 3 can fasten the carbon fiber 2 . With such a carbon-based yarn 3, by using a carbon-fiber cloth as the support layer 1, all the materials of the preform structure 10 can be made of a carbon-based material. Further, the strength of the preform structure 10 can be further improved.
  • Examples of the carbon-based yarn 3 include carbon nanotube yarn and carbon nanotube composite yarn of resin and carbon nanotube yarn (hereinafter sometimes referred to as “CNT composite yarn”).
  • a carbon nanotube yarn is, for example, a carbon nanotube forest (a growth body in which a plurality of carbon nanotubes are grown on a substrate so as to be oriented vertically to the substrate, and is sometimes referred to as an "array”. ), the carbon nanotube sheet is pulled out in a sheet form, and the pulled out carbon nanotube sheet is bundled, and then the bundle of carbon nanotubes is twisted to obtain a filamentous linear body.
  • a carbon nanotube yarn can be obtained by spinning a carbon nanotube dispersion.
  • the production of carbon nanotube filaments by spinning can be performed, for example, by the method disclosed in US Publication No. US 2013/0251619 (Japanese Patent Application Laid-Open No. 2012-126635). From the viewpoint of obtaining carbon nanotube yarns of high purity, it is preferable to obtain carbon nanotube yarns by twisting a carbon nanotube sheet.
  • the carbon nanotube yarn may be a yarn in which two or more carbon nanotube yarns are twisted together.
  • a CNT composite yarn for example, (1) a process to obtain a carbon nanotube yarn by drawing carbon nanotubes in a sheet form from the end of a carbon nanotube forest, bundling the drawn carbon nanotube sheet, and then twisting the bundle of carbon nanotubes.
  • a forest, sheet or bundle of carbon nanotubes, or a yarn in which a resin film is provided on the surface of the twisted yarn (2) a CNT composite yarn in which a bundle of carbon nanotubes is twisted together with yarns of other materials, ( 3) A CNT composite yarn obtained by twisting a yarn of another material with a carbon nanotube yarn or a CNT composite yarn.
  • the CNT composite yarn of (3) is a composite yarn when two yarns are knitted, but if at least one carbon nanotube or CNT composite yarn is included, three or more are twisted together. There may be.
  • the resin used for the CNT composite yarn is preferably a resin impregnated in the preform structure 10.
  • FIG. Since such a resin is the same as the resin of the resin layer 4 described later, the CNT composite yarn is easily impregnated with the resin.
  • the carbon-based yarn 3 is a twisted yarn, it is preferably Z twisted (left twisted). In the case of Z-twisting, it is possible to suppress unraveling of the thread when sewing with the carbon-based thread 3 using an embroidery machine.
  • the diameter of the carbon-based yarn 3 (in the case of twisted yarn, the diameter of the twisted yarn) is preferably 50 ⁇ m or more and 1000 ⁇ m or less. If the diameter of the carbon-based thread 3 is within the above range, the carbon-based thread 3 can hold the carbon fiber 2 more reliably.
  • the tensile strength of the carbon-based yarn 3 is preferably 500 MPa or more. If the tensile strength is 500 MPa or more, it is possible to prevent problems such as thread breakage when sewing with the carbon-based thread 3 .
  • the tensile strength of the carbon-based yarn 3 can be measured by the following method. That is, the carbon-based yarn 3 is cut to a length of 4 cm with a cutter, and 1.5 cm at each end of the carbon-based yarn 3 is attached to the mount with an adhesive (manufactured by Toagosei Co., Ltd., Aron Alpha EXTRA4020) so that the measured length is 1 cm. Fix it and prepare a test piece.
  • the method for manufacturing a preform structure according to the present embodiment is a method for manufacturing the preform structure according to the present embodiment, in which carbon fibers 2 are arranged on a support layer 1, carbon-based yarns 3 are is a method comprising a step of fixing the carbon fibers 2 to the support layer 1 (fixing step).
  • the carbon fibers 2 are first arranged on the support layer 1 .
  • the carbon fibers 2 can be arranged in various shapes.
  • the carbon fiber 2 may have a spiral shape as shown in FIG. 1, but is not limited to this.
  • Examples of the shape of the carbon fiber 2 include circular, elliptical, angular (triangular, quadrangular, pentagonal, hexagonal, etc.), star-shaped, wavy, linear, and the like.
  • the number of carbon fibers 2 is not particularly limited, and is preferably one or more, and more preferably two or more from the viewpoint of strength.
  • the carbon fibers 2 are then fastened to the support layer 1 by the carbon-based yarns 3 .
  • a known method can be appropriately adopted.
  • a method of fastening the carbon fiber 2 to the support layer 1 by sewing with the carbon-based thread 3 may be used.
  • the sewing method may be hand sewing or may use a device.
  • Devices used here include a sewing machine, an embroidery machine, and the like. Among these, it is preferable to use an embroidery machine.
  • a fiber-reinforced plastic 100 (see FIG. 4) according to the present embodiment includes the preform structure 10 according to the present embodiment and a resin impregnated in the preform structure 10 .
  • Resins used here include thermosetting resins and thermoplastic resins.
  • Thermosetting resins include epoxy resins, polyester resins, phenol resins, thermosetting polyimide resins, and the like. Among these, epoxy resins are preferable from the viewpoint of strength and the like.
  • thermoplastic resins include polypropylene resins, polyphenylene sulfide resins, polycarbonate resins, and thermoplastic polyurethane resins.
  • the fiber-reinforced plastic 100 can be produced, for example, by a method including a step of laminating a plurality of prepregs 20 shown in FIG. 3 (lamination step).
  • a prepreg 20 as shown in FIG. 3 is prepared.
  • the prepreg 20 can be produced by impregnating the preform structure 10 with resin and forming the resin layer 4 so as to cover the preform structure 10 .
  • the resin used here is a thermosetting resin
  • an uncured thermosetting resin is used.
  • a substrate portion is formed by laminating a plurality of preform structures 10 .
  • the inside of the base material portion is impregnated with resin, and the periphery of the base material portion is also covered with the resin layer 4 .
  • thermosetting resin When the resin is a thermosetting resin, a step of curing the thermosetting resin may be provided after the lamination step. After the lamination step, the thermosetting resin can be cured to produce the fiber-reinforced plastic 100 .
  • the carbon fibers 2 are arranged on the support layer 1 with a free design and are fastened by the carbon-based threads 3 . Therefore, the degree of freedom in designing the carbon fiber 2 can be increased.
  • a layer made of carbon fibers 2 with a free design can be formed on the support layer 1 . Therefore, if the support layer 1 is carbon fiber cloth, a preform structure 10 having two layers, a layer made of carbon fiber cloth and a layer made of free-designed carbon fibers 2, can be obtained.
  • the material of the substrate portion can be made entirely of a carbon-based material, and the strength of the substrate portion can be further improved.
  • delamination between the support layer 1 and the layer made of the carbon fibers 2 can be suppressed.
  • the support layer 1 is glass fiber cloth, delamination due to different materials such as glass fiber and carbon fiber can be suppressed.
  • the support layer 1 is preferably resin cloth or resin film.
  • the resin that is the material of the resin cloth or the resin film and the resin impregnated in the preform structure 10 are preferably the same material.
  • the support layer 1 and the resin layer 4 can be integrated.
  • the resin that is the material of the support layer 1 is a thermoplastic resin
  • the support layer 1 itself can be used as a resin impregnated in the preform structure 10, without providing the resin layer 4 separately. good.
  • a substrate portion having a layer made of carbon fibers 2 with a free design can be formed.
  • the following effect (5) can be achieved.
  • the support layer 1 and the resin layer 4 are made of the same material, the support layer 1 and the resin layer 4 can be integrated.
  • the present invention is not limited to the above-described embodiments, and includes modifications, improvements, etc. within the scope of achieving the object of the present invention.
  • the layer made of carbon fibers 2 was formed only on the upper surface of the support layer 1, but the present invention is not limited to this.
  • a layer made of carbon fibers 2 may be formed not only on the upper surface of the support layer 1 but also on the lower surface of the support layer 1 . In this way, a preform structure is obtained which has layers made of carbon fibers 2 of free design on both sides of the support layer 1 .
  • the fiber-reinforced plastic 100 is produced by laminating a plurality of prepregs 20, but the present invention is not limited to this.
  • the fiber-reinforced plastic 100 may be produced by laminating a plurality of preform structures 10 to form a base material portion, and then impregnating the base material portion with a resin. Further, in the above-described embodiment, when laminating a plurality of prepregs 20, the step of curing the thermosetting resin was performed after the lamination step, but the present invention is not limited to this.
  • the fiber-reinforced plastic 100 may be produced by bonding the prepregs 20 by hot pressing to cure the thermosetting resin in the lamination process.
  • 1 support layer, 11... warp thread, 12... weft thread, 2... carbon fiber, 3... carbon-based thread, 4... resin layer, 10... preform structure, 20... prepreg, 100... fiber reinforced plastic.

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  • Chemical & Material Sciences (AREA)
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PCT/JP2022/006160 2021-03-02 2022-02-16 プリフォーム構造体、繊維強化プラスチック、及びプリフォーム構造体の製造方法 Ceased WO2022185918A1 (ja)

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US18/279,585 US20240309159A1 (en) 2021-03-02 2022-02-16 Preform structure, fiber-reinforced plastic, and production method for preform structure
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US20100021682A1 (en) * 2008-07-25 2010-01-28 Florida State University Research Foundation Composite material and method for increasing z-axis thermal conductivity of composite sheet material
JP2012126635A (ja) 2010-11-22 2012-07-05 Furukawa Electric Co Ltd:The 凝集紡糸構造体の製造方法および凝集紡糸構造体
US20130251619A1 (en) 2010-11-22 2013-09-26 National Institute Of Advanced Industrial Science And Technology Aggregated thread structure, production method thereof, and electric wire using the same
WO2016147646A1 (ja) 2015-03-19 2016-09-22 東レ株式会社 シート状強化繊維基材、プリフォームおよび繊維強化樹脂成形品
WO2018199256A2 (ja) * 2017-04-26 2018-11-01 三菱電機株式会社 エレベータ、その懸架体、及びその製造方法

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US8246882B2 (en) * 2003-05-02 2012-08-21 The Boeing Company Methods and preforms for forming composite members with interlayers formed of nonwoven, continuous materials
EP2599614B1 (fr) * 2011-12-01 2016-03-02 Techspace Aero S.A. Procédé de réalisation d'une préforme et son utilisation dans la fabrication d'une pièce composite
WO2019008444A1 (en) * 2017-07-05 2019-01-10 Coats Group Plc FIBER BEAM FIBER PREFORM MIXED WITH OVERMOLDING
KR102189113B1 (ko) * 2019-03-28 2020-12-09 한국과학기술연구원 스티치 부재를 포함하는 섬유강화 복합 구조체 및 이의 제조 방법

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US20100021682A1 (en) * 2008-07-25 2010-01-28 Florida State University Research Foundation Composite material and method for increasing z-axis thermal conductivity of composite sheet material
JP2012126635A (ja) 2010-11-22 2012-07-05 Furukawa Electric Co Ltd:The 凝集紡糸構造体の製造方法および凝集紡糸構造体
US20130251619A1 (en) 2010-11-22 2013-09-26 National Institute Of Advanced Industrial Science And Technology Aggregated thread structure, production method thereof, and electric wire using the same
WO2016147646A1 (ja) 2015-03-19 2016-09-22 東レ株式会社 シート状強化繊維基材、プリフォームおよび繊維強化樹脂成形品
WO2018199256A2 (ja) * 2017-04-26 2018-11-01 三菱電機株式会社 エレベータ、その懸架体、及びその製造方法

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JPWO2022185918A1 (https=) 2022-09-09
US20240309159A1 (en) 2024-09-19
TW202239564A (zh) 2022-10-16
JP7836292B2 (ja) 2026-03-26
EP4282628B1 (en) 2026-04-01
EP4282628A1 (en) 2023-11-29

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