WO2022209454A1 - 扁平軽量部材およびその製造方法 - Google Patents
扁平軽量部材およびその製造方法 Download PDFInfo
- Publication number
- WO2022209454A1 WO2022209454A1 PCT/JP2022/007537 JP2022007537W WO2022209454A1 WO 2022209454 A1 WO2022209454 A1 WO 2022209454A1 JP 2022007537 W JP2022007537 W JP 2022007537W WO 2022209454 A1 WO2022209454 A1 WO 2022209454A1
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- Prior art keywords
- layer
- lightweight member
- flat
- skin layer
- reinforcing
- Prior art date
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- B32B2260/025—Particulate 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
- 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
-
- 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
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/20—Particles characterised by shape
- B32B2264/203—Expanded, porous or hollow particles
-
- 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
- B32B2603/00—Vanes, blades, propellers, rotors with blades
Definitions
- the present invention relates to a flat, lightweight member (fiber-reinforced resin molded article) that can be used as a propeller blade and is composed of a surface skin layer and an inner core layer, and a method for manufacturing the same.
- the present invention relates to a flat and lightweight member made of a fiber-reinforced resin that has excellent mechanical properties at the ends and adhesion between the core layer and the skin layer, has a good appearance quality, and has excellent productivity, and a method for producing the same.
- Fiber reinforced resin is used in a wide range of industrial fields due to its light weight, high strength, and high rigidity.
- a molded product using 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 preferably used.
- the flat lightweight member As a fiber-reinforced resin molded article having such a sandwich structure, a flat lightweight member composed of a skin layer made of a fiber-reinforced base material and a core layer made of lightweight particles and a matrix resin is known.
- the flat lightweight member means a member that has a structure in which the circumferential length and cross-sectional shape change in the longitudinal direction and that can be mainly used as a propeller blade.
- a propeller blade is known in which an upper surface prepreg and a lower surface prepreg are laminated and adhered in the thickness direction at the ends.
- This flat lightweight member is made by laminating a prepreg for the upper surface on one split mold and a prepreg for the lower surface on the other split mold, respectively, and arranging a foaming agent in the space formed by both prepregs when the molds are put together. can get.
- the main part is composed of a skin layer, a core layer, and a separation layer
- the peripheral part (the flat lightweight member when viewed from the direction in which the projected area is the largest)
- a flat lightweight member is known in which the outer peripheral part) is composed of a skin layer and a core layer, and further reinforcing fibers for reinforcement are additionally arranged in the parts corresponding to the leading edge and trailing edge when used as a propeller blade.
- a separation layer is arranged between the core layer and the skin layer to prevent passage of lightweight particles. After separation, only the matrix resin is impregnated into the dry reinforcing fiber base material constituting the skin layer to form the skin layer (for example, Patent Document 2).
- JP 2020-151876 A JP-A-8-276441 Japanese Patent No. 5272418
- the above-described flat lightweight member in which the prepreg for the upper surface and the prepreg for the lower surface are laminated and adhered in the thickness direction at the end requires a region for laminating and adhering both prepregs at the end.
- it becomes necessary to dispose prepreg having a large specific gravity even in a region that should be formed of a core layer that is originally lightweight and there is a problem that the weight of the flat lightweight member increases.
- the shape of the flat lightweight member to which such a configuration can be applied is limited.
- the main portion is composed of the skin layer, the core layer, and the separation layer
- the peripheral portion is composed of the skin layer and the core layer
- the portions corresponding to the leading edge and the trailing edge as described above are provided with reinforcing layers.
- Conventional flat lightweight members with additional reinforced fibers have the possibility of peeling near the separation layer after long-term use if the position of the separation layer is not appropriate. I had a problem I could't do.
- a conventional flat lightweight member is manufactured by laminating a prepreg for the upper surface on one split mold and a prepreg for the lower surface on the other split mold, respectively, and placing a foaming agent in the space formed by both prepregs when the molds are put together.
- it is necessary to laminate prepregs on the surface of a mold having a three-dimensional shape at room temperature and then heat the mold to harden the prepregs. There was a problem with productivity because it took a lot of time to heat and cool the mold.
- a conventional method for manufacturing a flat lightweight member in which a part of the matrix resin for forming the core layer is passed through the separation layer and impregnated and cured into the dry reinforcing fiber base material to form the skin layer,
- the flat lightweight member has a three-dimensional shape instead of a simple flat plate, it is difficult to obtain a flat lightweight member with high precision and small variations because the separation layers arranged separately at the top and bottom are displaced during molding.
- positioning of reinforcing fibers for reinforcement is difficult and tends to shift during fiber-reinforced resin molding.
- air bubbles called voids are generated at the ends, which may reduce the mechanical properties and spoil the appearance of the product.
- the problem of the present invention is to focus on the above problems, and to provide a flat and lightweight member that has excellent mechanical properties at the ends and adhesion between the core layer and the skin layer, has good appearance quality, and has excellent productivity. and a method for producing the same.
- a flat lightweight member wherein skin layers are arranged on both surfaces of the flat lightweight member, and end portions of the flat lightweight member are arranged so as to be in contact with both inner surfaces of the skin layers on both surfaces. and a core layer disposed in a space surrounded by the skin layer and the edge reinforcing layer so as to be in direct contact with the inner surface of the skin layer, wherein the skin layer is One or more layers comprising reinforcing fibers aligned in one direction and a first matrix resin, the end reinforcing layer comprising a fiber reinforced resin sheet, and the core layer comprising thermally expandable particles and a second matrix resin.
- a flat, lightweight member comprising a matrix resin.
- a preparatory step to prepare a first placement step of placing the one skin layer on the lower mold heated to a molding temperature, and placing the edge reinforcing layer on at least a part of the peripheral edge of the one skin layer; a step of placing a mixture of thermally expandable particles and a second matrix resin on the one skin layer; a second arranging step of further arranging the other skin layer on the top surface of the one skin layer to bring the edge reinforcing layer into contact with at least part of the peripheral edge of the other skin layer; a mold closing step of closing the upper mold heated to the molding temperature,
- a method for producing a flat lightweight member further comprising a step of volume-expanding the thermally expandable particles to form a core layer.
- the reinforcing fiber resin sheet is a prepreg made of reinforcing fibers aligned in one direction and a first matrix resin.
- the manufacturing method of the member (11) The method for producing a flat lightweight member according to (8) or (9) above, wherein the reinforcing fiber resin sheet is a fiber-reinforced foam containing reinforcing fibers. (12) The method of manufacturing a flat lightweight member according to any one of (8) to (11), wherein a notch prepreg is used as the prepreg.
- the flat lightweight member and the manufacturing method thereof according to the present invention it is possible to obtain a flat lightweight member that has excellent mechanical properties at the ends and adhesion between the core layer and the skin layer, has a good appearance quality, and has excellent productivity. be able to.
- FIG. 3A is a top view and (b) is a cross-sectional view taken along line AA' of an example of the flat lightweight member of the present invention.
- FIG. 2A is a cross-sectional view (a) showing an example of a raised skin layer, and an enlarged view showing an example of the raised skin layer in an example of the flat lightweight member of the present invention.
- FIG. 4 is a cross-sectional view showing an example of the positional relationship among the skin layer, the edge reinforcing layer and the core layer in the flat lightweight member of the present invention.
- FIG. 4 is a see-through top view showing an example of a closed space surrounded by a skin layer and end reinforcing layers in the flat lightweight member of the present invention; It is an example of an end reinforcing layer having a roll structure or a folded structure in the flat lightweight member of the present invention. It is a figure which shows each process in the manufacturing method of the flat lightweight member of this invention.
- FIG. 4 is a diagram showing each step in another manufacturing method of the flat lightweight member of the present invention;
- the flat lightweight member according to the present invention comprises skin layers arranged on both surfaces, and end reinforcing layers arranged so as to be in contact with both inner surfaces of the skin layers on both surfaces at the ends of the flat lightweight member. and a core layer disposed in a space surrounded by the skin layer and the edge reinforcing layer so as to be in direct contact with the inner surface of the skin layer.
- the skin layer is formed using one or more layers of prepreg made of unidirectionally aligned reinforcing fibers and a first matrix resin, and includes one or more layers of reinforcing fibers and a first matrix resin.
- the edge reinforcing layer includes a fiber-reinforced resin sheet
- the core layer includes thermally expandable particles as lightweight particles and a second matrix resin.
- FIG. 1 shows one embodiment of the flat lightweight member of the present invention used as a propeller blade.
- FIG. 1(a) shows a top view of the flat lightweight member 1, the right side of the paper surface is the tip portion a, and the left side of the paper surface is the root portion b.
- AA' section of this flat lightweight member 1 (that is, a section perpendicular to the longitudinal direction of the flat lightweight member 1) is shown in FIG. 1(b).
- This flat lightweight member 1 is mainly composed of skin layers 21 and 22, a core layer 30, and end reinforcing layers 40 and 41. As shown in FIG.
- the skin layers 21, 22 are arranged on both surfaces of the flat lightweight member 1, and the end reinforcing layers 40, 41 are attached to the ends (propeller blades) so as to contact both inner surfaces of the skin layers 21, 22 on both surfaces.
- the core layer 30 is arranged in a space surrounded by the skin layers 21, 22 and the end reinforcing layers 40, 41 so as to be in direct contact with the skin layers. ing.
- the skin layer in the present invention is mainly formed using a prepreg composed of reinforcing fibers aligned in one direction and the first matrix resin, and one layer containing the reinforcing fibers and the first matrix resin is used. Including above.
- the inner surface of the skin layer is the surface of the skin layer located on the inner surface side of the flat lightweight member.
- surface means the outer surface of the flat lightweight member.
- the thickest part of the skin layer constituting one surface of the flat lightweight member is preferably formed from two or more layers of prepreg, and preferably has four or more layers of prepreg. more preferred. That is, such a portion preferably has two or more layers containing reinforcing fibers and the first matrix resin, more preferably four or more layers.
- the thickness of the skin layer of the present invention is preferably 0.1 mm or more and 10 mm or less, more preferably 0.2 mm or more and 5 mm or less, and still more preferably 0.4 mm or more and 2 mm or less.
- the thickness is within the above preferable range, it becomes easy to uniformly conduct heat to the inside of the laminate during molding, and as a result, a flat and lightweight member with excellent appearance can be obtained.
- the skin layer is also preferably formed using prepregs having two or more orientation directions, more preferably using prepregs having three or more orientation directions. As a result, the skin layer has two or more, more preferably three or more orientation directions.
- a prepreg is obtained by preparing a plurality of prepregs in which reinforcing fibers are aligned in one direction and laminating them so that the orientation direction of the reinforcing fibers is shifted.
- preferable lamination configurations include two types of lamination configurations of 0 degrees and 90 degrees, three types of lamination configurations of 0 degrees and ⁇ 45 degrees, Preferred embodiments include a lamination structure including three types of 0 degrees and ⁇ 30 degrees and a lamination structure including four types of 0 degrees, ⁇ 45 degrees and 90 degrees.
- the skin layer uses one or more layers of unidirectional prepreg, which is a prepreg in which reinforcing fibers are aligned in one direction, and one or more layers of woven prepreg, which is a prepreg in which continuous fibers are woven.
- This is preferable from the viewpoint of achieving both impact properties and rigidity.
- the woven prepreg on the outermost surface of the flat lightweight member and arranging the unidirectional prepreg inside it so that the fiber direction is the longitudinal direction of the flat lightweight member, the woven fabric base material of the reinforcing fiber is provided on the outermost surface.
- a preferred embodiment is a flat lightweight member provided with a skin layer having reinforcing fibers arranged in one direction inside.
- the woven fabric base material derived from the woven prepreg suppresses breakage of the flat lightweight member due to the collision of a flying object, while the reinforcing fibers derived from the unidirectional prepreg are flat and lightweight. It becomes possible to bear the tensile stress applied in the longitudinal direction of the member.
- the edge reinforcing layer in the present invention is arranged on the peripheral edge of the flat lightweight member.
- the peripheral portion of the flat lightweight member as used in the present invention means the peripheral portion when the flat lightweight member is projected from above (that is, the flat lightweight member when viewed from the direction in which the projected area is the largest. part of the perimeter).
- the inner surface of the end reinforcing layer is the surface of the end reinforcing layer located on the inner surface side of the flat lightweight member.
- the edge reinforcing layer in the present invention includes a fiber reinforced resin sheet.
- the fiber-reinforced resin sheet is preferably composed of a prepreg made of reinforcing fibers aligned in one direction and the first matrix resin.
- the fiber-reinforced resin sheet is preferably composed of two or more layers of prepreg, and more preferably composed of four or more layers of prepreg.
- the edge reinforcing layer includes one or more layers composed of reinforcing fibers aligned in one direction and the first matrix resin.
- the fiber-reinforced resin sheet of the end reinforcing layer is a fiber-reinforced foam (porous body) containing reinforcing fibers.
- fiber-reinforced foams include sandwich structures (described, for example, in WO 14/162873), and foams with thermoplastic resin impregnated on one side and reinforcing fibers exposed on the other side.
- a nonwoven fabric for example, described in JP-A-2014-172201 can be exemplified.
- the cross-sectional area of the end reinforcing layer of the present invention is preferably 1 mm 2 or more and 1200 mm 2 or less, more preferably 5 mm 2 or more in a cross section perpendicular to the contour direction of the peripheral edge. 500 mm 2 or less.
- the edge reinforcing layer of the present invention preferably has fiber orientation along the contour of the peripheral edge.
- the laminate is arranged along the contour of the peripheral edge of a desired flat lightweight member to obtain a flat lightweight member.
- the fiber orientation can be in the direction along the contour of the periphery of the.
- the core layer in the present invention is in direct contact with the skin layer, unlike conventional flat lightweight members which have a separation layer between the skin layer and the core layer.
- the core layer and the skin layer can be firmly integrated, so that peeling is unlikely to occur in the vicinity of the separation layer even after long-term use.
- the core layer in the present invention is formed from a lightweight resin and a second matrix resin.
- the weight ratio of the lightweight particles (thermally expandable particles) and the second matrix in the core layer should be in the range of 5% or more and 100% or less of the lightweight particles when the weight of the second matrix resin is 100%. is preferable, and the range of 10% or more and 40% or less is more preferable.
- the weight of the lightweight particles By setting the weight of the lightweight particles to 5% or more, the specific gravity of the core layer becomes small, and lightness is easily exhibited.
- it 10% or more it is possible to reduce the partial "resin richness" caused by the separation of the second matrix resin from the lightweight particles, so that the core layer has a more homogeneous structure. Variation in the center of gravity can be reduced.
- the second matrix resin when the content is 100% or less, the second matrix resin is present between the lightweight particles to crosslink the lightweight particles, and the core layer becomes rigid and retains its shape. If it is more than 100%, cross-linking between the lightweight particles becomes insufficient, and the core layer becomes brittle and easily loses its shape. Furthermore, by making it 40% or less, the second matrix resin can cover the periphery of the lightweight particles, so that the occurrence of cracks in the core layer is suppressed, and the mechanical properties of the core layer can be maintained well for a long period of time. can.
- the fiber-reinforced resin sheet used in the present invention mainly consists of reinforcing fibers and a first matrix resin.
- the reinforcing fibers of the fiber-reinforced resin sheet may be continuous fibers or discontinuous fibers.
- the form of the fiber-reinforced resin sheet is not particularly limited, it is preferable to use a prepreg as the fiber-reinforced resin sheet from the viewpoint of mechanical properties. Moreover, from the viewpoint of lightness, it is preferable to use a fiber-reinforced resin foam as the fiber-reinforced resin sheet.
- the prepreg used in the present invention is mainly composed of reinforcing fibers and a first matrix resin.
- the volume content of the reinforcing fibers that are preferable for the prepreg is preferably 40% or more and 80% or less, more preferably 45% or more and 75% or less, and still more preferably 50% or more and 70% or less.
- the amount of the reinforcing fiber contained in the prepreg is preferably 50 g/m 2 or more and 1000 g/m 2 or less as the basis weight of the reinforcing fiber in the case of forming a sheet material. If the basis weight is too small, voids in which no reinforcing fibers are present may occur in the plane of the prepreg. By setting the basis weight to be equal to or higher than the lower limit of the above preferred range, it is possible to eliminate voids that serve as starting points for fracture. Further, if the basis weight is equal to or less than the upper limit of the preferable range, heat can be uniformly transferred to the inside during preheating for molding.
- the basis weight is more preferably 100 g/m 2 or more and 600 g/m 2 or less, still more preferably 150 g/m 2 or more and 400 g/m 2 or less, in order to achieve both structural uniformity and heat transfer uniformity. be.
- the basis weight of the reinforcing fiber is measured by cutting out a 10 cm square area from the reinforcing fiber sheet, measuring the mass, and dividing by the area. The measurement is performed 10 times for different parts of the reinforcing fiber sheet, and the average value is adopted as the basis weight of the reinforcing fiber.
- the reinforcing fibers used in the fiber-reinforced resin sheet, prepreg, and fiber-reinforced foam include, for example, aramid fibers, polyethylene fibers, organic fibers such as polyparaphenylene benzoxdol (PBO) fibers, glass fibers, and carbon fibers.
- Inorganic fibers such as fibers, silicon carbide fibers, alumina fibers, tyranno fibers, basalt fibers, and ceramic fibers, metal fibers such as stainless steel fibers and steel fibers, boron fibers, natural fibers, modified natural fibers, and the like.
- carbon fiber is particularly lightweight among these reinforcing fibers, and has particularly excellent properties in terms of specific strength and specific elastic modulus, and is also excellent in heat resistance and chemical resistance. It is suitable for members such as automobile panels and wings for aircraft propulsion devices, where it is desired to reduce the Among these, PAN-based carbon fibers are preferable because high-strength carbon fibers are easily obtained.
- the first matrix resin and the second matrix resin are in a cured state.
- Examples of the first matrix resin used in the prepreg of the present invention include epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins, epoxy acrylate resins, urethane acrylate resins, phenoxy resins, alkyd resins, urethane resins, and maleimide resins.
- thermosetting resin such as cyanate resin, polyamide resin, polyacetal resin, polyacrylate resin, polysulfone resin, acrylic butadiene styrene (ABS) resin, polyester resin, acrylic resin, polybutylene terephthalate (PBT) resin, polyethylene Terephthalate (PET) resin, polyethylene resin, polypropylene resin, polyphenylene sulfide (PPS) resin, polyether ether ketone (PEEK) resin, liquid crystal polymer, vinyl chloride, fluorine resin such as polytetrafluoroethylene, thermoplastic resin such as silicone is mentioned.
- a thermosetting resin Since the first matrix resin is a thermosetting resin, the prepreg has tackiness at room temperature. It is possible to mold while maintaining the laminated structure as described.
- Examples of the second matrix resin used in the core layer of the present invention include epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins, epoxy acrylate resins, urethane acrylate resins, phenoxy resins, alkyd resins, urethane resins, Thermosetting resins such as maleimide resins and cyanate resins, polyamide resins, polyacetal resins, polyacrylate resins, polysulfone resins, acrylic butadiene styrene (ABS) resins, polyester resins, acrylic resins, polybutylene terephthalate (PBT) resins, Polyethylene terephthalate (PET) resin, polyethylene resin, polypropylene resin, polyphenylene sulfide (PPS) resin, polyether ether ketone (PEEK) resin, liquid crystal polymer, vinyl chloride, fluorine resins such as polytetrafluoroethylene, thermoplastics such as silicone resin. Moreover, it is preferable
- the glass transition temperature of the first matrix resin is higher than the glass transition temperature of the second matrix resin.
- the lightweight particles of the flat lightweight member of the present invention mean heat-expandable resin particles that expand in volume when heated during molding, and heat-expandable particles that are already in a thermally expanded state but can be compressed by pressurization. do.
- the thermally expandable particles When the thermally expandable particles are mixed with the second matrix resin and heated, they expand in volume.
- the second matrix resin is a thermosetting resin
- the thermosetting resin hardens to form a core having a lightweight porous structure. form a layer.
- the second matrix resin is a thermoplastic resin
- the molten thermoplastic resin solidifies during cooling, or the softened thermoplastic resin binds to form a core layer with a lightweight porous structure. .
- the volume expansion coefficient ⁇ is preferably in the range of 30% or more and 2000% or less, although it varies depending on the weight ratio of the thermally expandable particles and the second matrix resin and the heating conditions during molding.
- thermally expandable particles examples include polyacrylonitrile-based copolymers, polymethacrylonitrile-based copolymers, polyvinylidene chloride-based copolymers, polystyrene or polystyrene-based copolymers, polyolefins, and polyphenylene oxide-based copolymers. It is preferably a capsule-like particle containing a heat-expandable gas inside.
- thermally expandable particles using hydrocarbons with a low boiling point as the thermally expandable gas are preferable because they have a large volume expansion coefficient and can form a lightweight core layer.
- the average particle size before volume expansion is preferably in the range of 1 ⁇ m to 1 mm.
- the average particle size is set to 1 ⁇ m or more, it is possible to suppress leakage of the thermally expandable particles to the surface of the flat lightweight member due to resin flow during molding.
- the thickness is set to 1 mm or less, the heat-expandable particles penetrate into the thin portion of the core layer, so that the weight of the core layer can be reduced, and the density unevenness between the heat-expandable particles and the second matrix resin in the core layer can be reduced.
- thermally expandable particles include "Matsumoto Microsphere” (registered trademark) manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd., “Expancel” (registered trademark) manufactured by Nobel Co., Ltd., “ eslen beads” and the like, but the present invention is not limited to these products.
- thermally expandable particles only one type of thermally expandable particles may be used as the lightweight particles, or a mixture of multiple types of thermally expandable particles may be used. Also, the thermally expandable particles may be used alone, or may be used in combination with non-thermally expandable particles such as glass beads.
- the reinforcing fibers raised from the skin layer penetrate into the core layer.
- FIG. 2 shows one embodiment of the flat lightweight member of the present invention.
- FIG. 2(a) is a sectional view showing an example of the raised skin layer of the flat lightweight member 1
- FIG. 2(b) is the flat lightweight member.
- An enlarged view of an example of the raised skin layer in 1 is shown.
- FIG. 2(b) shows the skin layer 22, the raised reinforcing fibers 200, the core layer 30, and the fiber reinforced portion 300 of the core layer partially reinforced by the penetration of the raised reinforcing fibers.
- the state in which the reinforcing fibers are raised means a state in which one or more reinforcing fibers protrude in the out-of-plane direction from the surface (surface with the largest surface area) of the fiber-reinforced resin sheet, prepreg, or fiber-reinforced foam.
- the lower limit of the length of the protruding reinforcing fibers is preferably 0.1 mm or longer, more preferably 0.5 mm or longer, and even more preferably 1 mm or longer. If it is below the lower limit, there is a concern that the reinforcing fibers that have entered the core layer may come off.
- the upper limit of the length of the protruding reinforcing fibers is preferably 100 mm or less, more preferably 50 mm or less, and even more preferably 10 mm or less. If the upper limit is exceeded, the reinforcing fibers may break during raising.
- the length of the raised reinforcing fiber can be determined by embedding and polishing the area including the boundary between the skin layer and the core layer as shown in FIG. Determined by measuring fiber length. It is preferable that the raised reinforcing fibers are continuously connected from the skin layer to the core layer, and such a structure can strengthen the adhesion between the skin layer and the core layer.
- the reinforcing fibers raised from the end reinforcing layer penetrate into the core layer.
- the raised reinforcing fibers are continuously connected from the edge reinforcing layer to the core layer, and such a structure can strengthen the adhesion between the edge reinforcing layer and the core layer.
- the space surrounded by the skin layer and the end reinforcing layer is a closed space. That is, it is preferable that the periphery of the core layer is covered with the skin layer and the edge reinforcing layer.
- FIG. 3 shows an example of a cross section of the flat lightweight member of the present invention (a cross section in the same direction as the AA' cross section shown in FIG. 1).
- the skin layers 21 and 22 completely reach both ends c and d of the flat lightweight member, and the entire surface of the flat lightweight member is covered with the skin layers 21 and 22 .
- the end reinforcing layers 40 and 41 are exposed on the surface of the flat lightweight member.
- one end c of the flat lightweight member is covered with the skin layer 23, and the end reinforcing layer 41 is exposed on the surface of the flat lightweight member at the other end d.
- FIG. 3 shows an example of a cross section of the flat lightweight member of the present invention (a cross section in the same direction as the AA' cross section shown in FIG. 1).
- the skin layers 21 and 22 completely reach both ends c and d of the flat lightweight member, and the entire surface of the flat lightweight member is covered with the skin layers 21 and 22 .
- the end reinforcing layers 40 and 41 are exposed on the surface
- the skin layers 21 and 22 completely reach both ends of the flat lightweight member, and the skin layers 21 and 22 extend between both ends of the flat lightweight member (the one end c and and the other end d) to form an internal reinforcing layer 25 .
- the internal reinforcing layer 25 can be formed by partially increasing the thickness of the skin layer, or by placing a prepreg laminate other than the skin layer between the skin layers 21 and 22, or by using the edge reinforcing layer.
- a method of arranging reinforcing fibers having the same configuration as in the skin layers 21 and 22 between the skin layers 21 and 22, and a part having a shape of an internal reinforcing layer by arranging reinforcing fibers such as prepreg around the core to form the skin layers 21 and 22 can be formed by, for example, a method of arranging between A cross section in which such an internal reinforcing layer is arranged can bear a large amount of shear load applied to the cross section, so that it is a preferred embodiment having excellent mechanical properties.
- the entire surface of the flat lightweight member is covered with the skin layers 21, 22 and the end reinforcing layers 40, 41, and the skin layers 21, 22 and the end portions are covered. It can be seen that the area surrounded by the partial reinforcing layers 40 and 41 is closed.
- the skin layer and the edge reinforcing layer form one closed area in FIGS. 3(a) to 3(c) and two closed areas in FIG. 3(d).
- FIG. 4 is an example of a see-through top view of the flat lightweight member of the present invention, showing a closed space 50 in which the core layer of the present invention is arranged and its contour 500.
- FIG. The closed space 50 exists inside the surface of the flat lightweight member 1, and is composed of the closed area described in FIG. 3 from the tip a to the root b in FIG. Furthermore, the closed space 50 is closed by the skin layer and the end reinforcing layer, or by the laminate of prepregs different from the skin layer and the skin layer at the tip a and the root b. Therefore, the core layer of the present invention arranged in the closed space 50 is not exposed on the surface of the flat lightweight member 1 .
- FIG. 4(a) illustrates a case where the flat lightweight member of the present invention has one closed space.
- FIG. 4(b) illustrates a case where the flat lightweight member of the present invention has two parallel closed spaces from the tip a to the root b.
- FIG. 4(c) illustrates a case where the flat lightweight member of the present invention has three discontinuous closed spaces from the tip a to the base b.
- the space between the plurality of closed spaces is an internal reinforcing layer formed by uniting the skin layer, which can be formed by partially increasing the thickness of the skin layer.
- the edge reinforcing layer is arranged on the entire peripheral portion.
- the reinforcing fibers raised from the skin layer and the end reinforcing layer penetrate into the core layer.
- a cut prepreg is a prepreg having cuts that are regularly distributed over the entire surface of the prepreg, and the continuous reinforcing fibers that make up the prepreg are cut at the locations of the cuts.
- Such regularly distributed cuts can be provided, for example, by the method described in the above-mentioned Patent Document 3.
- the incised prepreg can be used for the skin layer and edge reinforcing layer in combination with a normal prepreg that does not have incisions, and which is made up of only continuous reinforcing fibers.
- the incised prepreg With the incised prepreg, openings and deviations are more likely to occur at the incision insertion point, and the extensibility of the prepreg in the direction of the reinforcing fibers is improved.
- the flow at the time of compression molding opens the incision insertion point and separates the fiber bundles of the reinforcing fibers, thereby exhibiting flexibility as a prepreg and increasing the fluidity.
- the reinforcing fibers reach the ends, and the region where the resin is excessive is reduced, and a flat and lightweight member excellent in mechanical properties and appearance can be obtained. From the viewpoint of fluidity, it is preferable that the cuts be made throughout the thickness direction of the prepreg.
- cut prepreg for the skin layer is preferable because the reinforcing fibers are easily raised and can penetrate into the core layer to form a strong adhesive surface.
- the ends of the raised reinforcing fibers can penetrate into the core layer, the raised reinforcing fibers can penetrate deep into the core layer, and the adhesion between the core layer and the skin layer can be strengthened. .
- An integrated laminate of a prepreg without cuts and a prepreg with cuts may be used as the skin layer. At this time, it is preferable to dispose the cut prepreg on the contact surface with the core layer.
- Such an aspect is a preferable aspect in which the prepreg without cuts exhibits excellent mechanical properties, and the prepreg with cuts can strengthen the adhesion between the core layer and the skin layer.
- cut prepreg for the edge reinforcing layer is because it can suppress tension in the fiber direction when the edge reinforcing layer is pressed against the edge contour of the flat lightweight member and deformed as the core layer expands. This is preferable in that the occurrence of "resin-rich" and voids is suppressed, and the appearance quality and mechanical properties at the end portion are likely to be improved.
- the fiber direction of the reinforcing fibers of the end reinforcing layer is preferably along the contour of the end of the flat lightweight member.
- the fiber-reinforced resin sheet in the end reinforcing layer preferably has a roll structure or a folded structure.
- FIG. 5(a) An example of a roll structure is shown in FIG. 5(a), and an example of a folding structure is shown in FIG. 5(b).
- the end reinforcing layer having a scroll structure can be easily adjusted in thickness and cross-sectional area by adjusting the amount of winding a fiber reinforced resin sheet such as prepreg, and is also easy to manufacture. It can be used particularly preferably when the has a rounded shape.
- the end reinforcing layer having a folded structure can be easily adjusted to have a thinner thickness than the roll structure by adjusting the width of folding the fiber reinforced resin sheet such as prepreg and adjusting the number of folding times. It can be particularly suitably used when the end of the flat lightweight member has a sharp shape. That is, in FIGS. 3A to 3D, the end reinforcing layer 40 preferably has a roll structure, and the end reinforcing layer 41 preferably has a folded structure.
- a method for producing a flat lightweight member according to the present invention is a method for producing a flat lightweight member using a double-sided mold consisting of an upper mold and a lower mold, wherein reinforcing fibers aligned in one direction and a first matrix resin are used.
- FIG. 6 shows each step in the manufacturing method of the flat lightweight member of the present invention. molding.
- FIG. 6(a) is a preparation step, in which one skin layer 22, the other skin layer 21, and the end reinforcing layers 40, 41 are prepared.
- the skin layers 21 and 22 can be produced, for example, by cutting a prepreg cut body having a desired shape and desired fiber orientation from a sheet-like prepreg, and then laminating the prepreg cut bodies as necessary.
- a sheet-like prepreg can be laminated in a desired fiber orientation and then cut into a desired shape.
- the end reinforcing layer can be manufactured by laminating fiber-reinforced resin sheets to a predetermined thickness and then cutting them to a predetermined width, or by pultrusion molding or extrusion molding to form an elongated string-like member.
- the edge reinforcing layer has a roll structure
- it can be obtained, for example, by winding one fiber-reinforced resin sheet in order from the edge. Furthermore, for example, it can also be produced by folding a single fiber-reinforced resin sheet and then winding it.
- a roll structure can also be obtained from a laminate of a plurality of fiber-reinforced resin sheets by the same procedure.
- the end reinforcing layer When the end reinforcing layer has a folded structure, it is produced by, for example, folding one fiber-reinforced resin sheet in two or three and then folding it further. Further, for example, a thin scroll structure having a flat cross-sectional shape may be produced from one fiber-reinforced resin sheet, and then folded. Separately, a folded structure can also be obtained from a laminate of a plurality of fiber-reinforced resin sheets by the same procedure.
- prepreg When using prepreg as a fiber-reinforced sheet, it can be produced by laminating sheet-shaped prepreg cut into long strips or tape-shaped prepreg slit tape. Moreover, when a fiber-reinforced foam is used as the fiber-reinforced sheet, it can be manufactured by cutting a sheet-like fiber-reinforced foam into long and thin pieces.
- FIG. 6(b) shows the first placement step.
- one skin layer 22 is placed on a lower mold 82 heated to the molding temperature, and the edge reinforcing layers 40 and 41 are placed on at least a part of the peripheral edge of one skin layer 22 .
- the molding temperature set as the temperature of the lower mold depends on the types of the first matrix resin and the second matrix resin, but in the case of using a thermosetting resin, the temperature range is from 80°C to 230°C. preferable. A temperature of 80° C. or higher can promote the reaction of the matrix resin, and a temperature of 230° C. or lower can suppress decomposition of the matrix resin.
- the manufacturing method of the present invention since there is no need to raise or lower the temperature of the mold, the production time can be shortened as compared with the conventional method of raising or lowering the temperature of the mold.
- one skin layer may be placed on the lower mold as it is in a planar state, or may be placed on the lower mold after being formed into a three-dimensional shape in advance.
- the linear edge reinforcing layer may be arranged while being bent along the peripheral edge of one of the skin layers, or may be arranged along the shape of the peripheral edge in advance.
- the tack of the prepreg integrates the skin layer and the edge reinforcing layer, so positioning of the edge reinforcing layer is easy, which is preferable.
- This step is a step of placing a mixture 90 of lightweight particles (thermally expandable particles) and a second matrix resin on the inner surface of one skin layer 22 .
- care must be taken so that the mixture of the lightweight particles and the second matrix resin does not flow out of one of the skin layers beyond the edge reinforcing layer. Therefore, it is preferable that the mixture does not adhere to the edge reinforcing layer where the other skin layer contacts.
- a mixture of the lightweight particles and the second matrix resin is put inside the peripheral edge portion and kept inside the peripheral edge portion, so that the lightweight particles spread from between the end reinforcing layer and the skin layer to the surface of the flat lightweight member. can be prevented from leaking into the Moreover, it is preferable to add the mixture of the lightweight particles and the second matrix resin so as to coat the entire inner surface of one of the skin layers, since a homogeneous core layer can be obtained.
- the charging step it is preferable to preheat the mixture of the lightweight particles and the second matrix resin.
- the viscosity of the mixture of the lightweight particles and the second matrix resin is lowered, so that the charging time can be shortened and the charging amount can be easily adjusted.
- the mixture of lightweight particles and second matrix resin can be preheated using an oven or microwave.
- FIG. 6(d) shows the second placement step.
- the other skin layer 21 is further placed on the upper surface of the one skin layer 22 to bring the edge reinforcing layers 40 and 41 into contact with at least part of the peripheral edge of the other skin layer 22 .
- the other skin layer may be placed on the lower mold as it is in a planar state, or may be placed on the lower mold after being formed into a three-dimensional shape in advance.
- the tack of the prepreg integrates the skin layer and the edge reinforcing layer, so positioning of the edge reinforcing layer is easy, which is preferable.
- FIG. 6(e) is a mold closing step, which is a step of closing the upper mold 81 heated to the molding temperature.
- the mold closing process one skin layer, the edge reinforcing layer and the other skin layer are pressed and integrated. It is preferable to set the temperature of the upper mold to the same temperature as the temperature of the lower mold, but the manufacturing method of the flat lightweight member of the present invention is not limited to this. Also, the inside of the cavity can be evacuated during the mold closing process. By using such a method, the voids in the skin layer and the edge reinforcing layer are reduced, and the mechanical properties of the flat and lightweight member are improved. It is obtainable and desirable.
- the mold closing process is completed when the two-sided mold consisting of the upper mold and the lower mold is completely closed.
- the lightweight particles which are thermally expandable particles, start volumetric expansion after reaching a predetermined temperature to form a core layer. Due to the expansion of the lightweight particles, the skin layers and edge reinforcing layers are forced and pressed against the mold cavity by the core layer. After that, by curing and demolding as shown in FIG. 6(g), a flat lightweight member of excellent quality can be obtained.
- a method for producing a flat lightweight member according to the present invention is a method for producing a flat lightweight member using a double-sided mold consisting of an upper mold and a lower mold, wherein reinforcing fibers aligned in one direction and a first matrix resin are used.
- a preparation step of preparing a skin layer with an edge reinforcing layer, in which the edge reinforcing layer is bonded to the peripheral edge of one skin layer, and the other skin layer, using a prepreg consisting of the skin with the edge reinforcing layer A first placement step of placing the layer in the lower mold heated to the molding temperature, a loading step of placing a mixture of lightweight particles and a second matrix resin on the inner surface of the one skin layer, and the other skin layer.
- the lightweight particles are volume-expanded to form a core layer.
- FIG. 7 shows each step in more detail, in this method also, a double-sided mold is used in which a cavity in the shape of a flat lightweight member is formed on the mating surfaces of the upper mold and the lower mold, and the fiber reinforced resin is molded. do.
- FIG. 7A shows a preparatory step, in which end reinforcing layers 40 and 41 made of fiber-reinforced resin sheets are replaced with one skin made of prepreg made of reinforced fibers aligned in one direction and a first matrix resin.
- This is a step of preparing a skin layer with an edge reinforcing layer adhered to at least a part of the peripheral edge of the layer 22 and the other skin layer 21 made of prepreg.
- the skin layer and the edge reinforcing layer can be manufactured by the methods described above.
- a skin layer with an edge reinforcing layer can be manufactured by adhering an edge reinforcing layer to the peripheral edge of one of the skin layers.
- the skin layer and the edge reinforcing layer can be adhered by the tack of the prepreg.
- a thermoplastic resin is used as the first matrix resin, the edge reinforcing layer and one skin layer are heated to the melting temperature of the thermoplastic resin, pressed, and cooled to bond them together.
- the edge reinforcing layer can be adhered to one of the skin layers using a resin adhesive or a resin adhesive film.
- FIG. 7(b) shows the first placement step
- FIG. 7(c) shows the loading step
- FIG. 7(d) shows the second placement step
- FIG. 7(e) shows the mold closing step. shown.
- a cut prepreg as the prepreg.
- the use of the cut prepreg for the skin layer is preferable because the reinforcing fibers are likely to be raised, and the raised reinforcing fibers can penetrate deep into the core layer to form a strong adhesive surface.
- an integrated laminate of a prepreg without cuts and a prepreg with cuts may be used. At this time, it is preferable to dispose the cut prepreg on the side of the contact surface with the core layer.
- the prepreg without cuts exhibits excellent mechanical properties, and the prepreg with cuts can strengthen the adhesion between the core layer and the skin layer.
- cut prepreg for the edge reinforcing layer is because it can suppress tension in the fiber direction when the edge reinforcing layer is pressed against the edge contour of the flat lightweight member and deformed as the core layer expands. This is preferable in that the generation of "resin-rich" and voids can be suppressed, and the appearance quality and mechanical properties at the end portion can be improved.
- the fiber direction of the reinforcing fibers of the end reinforcing layer is preferably along the contour of the end of the flat lightweight member.
- the method for manufacturing a flat lightweight member it is preferable to raise the inner surface of at least one of the skin layers by the time the mold closing process is completed.
- a mixture of the lightweight particles and the second matrix resin is applied to the entire inner surface of one of the skin layers using a spatula or the like, whereby the reinforcing fibers on the inner surface of the skin layer can be raised. .
- the reinforcing fibers on the inner surface of the skin layer can be raised.
- the preheating temperature is preferably 40° C. or higher and 180° C. or lower, more preferably 70° C. or higher and 130° C. or lower, although it depends on the molding temperature and the expansion start temperature of the lightweight particles.
- the viscosity of the second matrix resin is lowered so that the resin can flow.
- the resin can be applied over a long period of time.
- the fiber-reinforced foam is used as the edge reinforcing layer, the fiber-reinforced foam is heated in the mold, and the reinforcing fibers contained in the fiber-reinforced foam are raised due to the springback of the reinforcing fibers, and penetrate into the core layer. By doing so, the core layer and the edge reinforcing layer are firmly integrated.
- the method for producing a flat lightweight member according to the present invention can be applied to the production of any flat lightweight member, and the obtained flat lightweight member can be used, for example, in propeller blade structures in the fields of sports and leisure, as well as in transportation vehicles such as aircraft, automobiles, and ships. preferably used as
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Abstract
Description
(1)扁平軽量部材であって、前記扁平軽量部材の両表面に配置されたスキン層と、前記扁平軽量部材の端部において前記両表面のスキン層の両内表面に接触するように配置された端部補強層と、前記スキン層と前記端部補強層とで囲まれた空間に、前記スキン層の内表面と直接接触するように配置されたコア層とを有し、前記スキン層は一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなる層を1層以上含み、前記端部補強層は繊維強化樹脂シートを含み、前記コア層は熱膨張性粒子と第2のマトリックス樹脂とを含むことを特徴とする、扁平軽量部材。
(2)前記繊維強化樹脂シートが一方向に引き揃えられた強化繊維と第1のマトリックス樹脂であることを特徴とする、前記(1)に記載の扁平軽量部材。
(3)前記繊維強化樹脂シートが強化繊維を含む繊維強化フォームであることを特徴とする、前記(1)に記載の扁平軽量部材。
(4)前記スキン層から起毛した強化繊維が前記コア層に侵入していることを特徴とする、前記(1)から(3)のいずれかに記載の扁平軽量部材。
(5)前記端部補強層から起毛した強化繊維が前記コア層に侵入していることを特徴とする、前記(1)から(4)のいずれかに記載の扁平軽量部材。
(6)前記スキン層と前記端部補強層で囲まれた空間が閉空間であることを特徴とする、前記(1)から(5)のいずれかに記載の扁平軽量部材。
(7)前記端部補強層において、前記繊維強化樹脂シートが巻物構造または折畳構造を有することを特徴とする、前記(1)から(6)のいずれかに記載の扁平軽量部材。
(8)上型と下型からなる両面型を用いた扁平軽量部材の製造方法であって、
一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグを用いて、一方のスキン層と他方のスキン層とを準備するとともに、繊維強化樹脂シートを用いて端部補強層を準備する準備工程と、
前記一方のスキン層を成形温度に加熱した前記下型に配置し、前記端部補強層を前記一方のスキン層の周縁部の少なくとも一部に載置する第1配置工程と、
熱膨張性粒子と第2のマトリックス樹脂との混合物を前記一方のスキン層上に載置する投入工程と、
前記他方のスキン層を前記一方のスキン層の上面にさらに配置して前記端部補強層を前記他方のスキン層の周縁部の少なくとも一部に接触させる第2配置工程と、
成形温度に加熱した前記上型を閉じる型閉じ工程と、を有し、
さらに、前記熱膨張性粒子を体積膨張させてコア層とする工程を有することを特徴とする、扁平軽量部材の製造方法。
(9)上型と下型からなる両面型を用いた扁平軽量部材の製造方法であって、
繊維強化樹脂シートからなる端部補強層を、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグからなる一方のスキン層の周縁部の少なくとも一部に接着し、端部補強層付きスキン層を準備するとともに、前記プリプレグからなる他方のスキン層を準備する準備工程と、
前記端部補強層付きスキン層を成形温度に加熱した前記下型に配置する第1配置工程と、
熱膨張性粒子と第2のマトリックス樹脂との混合物を前記一方のスキン層上に載置する投入工程と、
前記他方のスキン層を前記端部補強層付きスキン層の上面にさらに配置して前記端部補強層を前記他方のスキン層の周縁部の少なくとも一部に接触させる第2配置工程と、
成形温度に加熱した前記上型を閉じる型閉じ工程と、を有し、
さらに、前記熱膨張性粒子を体積膨張させてコア層とする工程を有することを特徴とする、扁平軽量部材の製造方法。
(10)前記強化繊維樹脂シートが、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグであることを特徴とする、前記(8)または(9)に記載の扁平軽量部材の製造方法。
(11)前記強化繊維樹脂シートが、強化繊維を含む繊維強化フォームであることを特徴とする、前記(8)または(9)に記載の扁平軽量部材の製造方法。
(12)前記プリプレグとして、切込プリプレグを用いることを特徴とする、前記(8)から(11)のいずれかに記載の扁平軽量部材の製造方法。
(13)少なくとも前記一方のスキン層の、扁平軽量部材における内表面に相当する部位を、前記型閉じ工程の完了までに起毛させることを特徴とする、前記(8)から(12)のいずれかに記載の扁平軽量部材の製造方法。
(14)前記端部補強層の、扁平軽量部材における内表面に相当する部位を、前記型閉じ工程の完了までに起毛させることを特徴とする、前記(8)から(13)のいずれかに記載の扁平軽量部材の製造方法。
本発明におけるスキン層は、主に、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグを用いて形成され、強化繊維と第1のマトリックス樹脂とを含む層を1層以上含む。
本発明における端部補強層は、扁平軽量部材の周縁部に配置される。本発明でいう扁平軽量部材の周縁部とは、扁平軽量部材を上部から投影した時の周囲部分(すなわち、扁平軽量部材を最も投影面積が大きくなる方向から見た場合の、該扁平軽量部材の外周の部分)を意味する。また、端部補強層の内表面とは、端部補強層において扁平軽量部材の内面側に位置する表面である。
本発明におけるコア層は、スキン層とコア層との間に分離層を有する従来の扁平軽量部材とは異なり、スキン層に直接接触している。このような構成とすることで、コア層とスキン層を強固に一体化できるため、長期にわたって使用しても分離層近傍で剥離を生じにくい。
本発明で使用される繊維強化樹脂シートは、主に、強化繊維と第1のマトリックス樹脂からなる。
本発明で使用されるプリプレグは、主に、強化繊維と第1のマトリックス樹脂から構成される。
本発明において、繊維強化樹脂シート、プリプレグ、および繊維強化フォームに用いられる強化繊維としては、例えば、アラミド繊維、ポリエチレン繊維、ポリパラフェニレンベンズオキサドール(PBO)繊維などの有機繊維、ガラス繊維、炭素繊維、炭化ケイ素繊維、アルミナ繊維、チラノ繊維、玄武岩繊維、セラミックス繊維などの無機繊維、ステンレス繊維やスチール繊維などの金属繊維、その他、ボロン繊維、天然繊維、変性した天然繊維などが挙げられる。その中でも特に炭素繊維は、これら強化繊維の中でも軽量であり、しかも比強度および比弾性率において特に優れた性質を有しており、さらに耐熱性や耐薬品性にも優れていることから、軽量化が望まれる自動車パネルや航空機推進装置用の羽などの部材に好適である。なかでも、高強度の炭素繊維が得られやすいPAN系炭素繊維が好ましい。
本発明の扁平軽量部材において、第1のマトリックス樹脂と第2のマトリックス樹脂は硬化した状態にある。
本発明の扁平軽量部材に係る軽量粒子は、成形時に加熱昇温することにより体積膨脹を起こす熱膨脹性樹脂粒子、および、すでに熱膨脹した状態にあるが加圧により圧縮され得る熱膨張性粒子を意味する。
α=100×(V2-V1)÷V1・・・(1)
本発明における扁平軽量部材においては、スキン層から起毛した強化繊維がコア層に侵入してなることが好ましい。
本発明に係る扁平軽量部材の製造方法は、上型と下型からなる両面型を用いた扁平軽量部材の製造方法であって、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグを用いて、一方のスキン層と他方のスキン層とを準備するとともに、繊維強化樹脂シートを用いて端部補強層を準備する準備工程と、前記一方のスキン層を成形温度に加熱した前記下型に配置し、前記端部補強層を前記一方のスキン層の周縁部の少なくとも一部に載置させる第1配置工程と、軽量粒子(熱膨張性粒子)と第2のマトリックス樹脂との混合物を前記一方のスキン層内表面上(最終的に得られる扁平軽量部材における、スキン層の内側面)に載置させる投入工程と、前記他方のスキン層を前記一方のスキン層の上面にさらに配置して前記端部補強層を前記他方のスキン層の周縁部の少なくとも一部に接触させる第2配置工程と、成形温度に加熱した前記上型を閉じる型閉じ工程と、を有し、さらに、前記軽量粒子を体積膨張させてコア層とする工程を有することを特徴とするものである。
21、22、23 スキン層
200 スキン層の起毛した強化繊維
30 コア層
300 スキン層の起毛した強化繊維が部分的に侵入したコア層の繊維強化部
40、41 端部補強層
50 閉空間
500 閉空間の輪郭
81 上型
82 下型
90 混合物
Claims (14)
- 扁平軽量部材であって、前記扁平軽量部材の両表面に配置されたスキン層と、前記扁平軽量部材の端部において前記両表面のスキン層の両内表面に接触するように配置された端部補強層と、前記スキン層と前記端部補強層とで囲まれた空間に、前記スキン層の内表面と直接接触するように配置されたコア層とを有し、前記スキン層は一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなる層を1層以上含み、前記端部補強層は繊維強化樹脂シートを含み、前記コア層は熱膨張性粒子と第2のマトリックス樹脂とを含むことを特徴とする、扁平軽量部材。
- 前記繊維強化樹脂シートが一方向に引き揃えられた強化繊維と第1のマトリックス樹脂であることを特徴とする、請求項1に記載の扁平軽量部材。
- 前記繊維強化樹脂シートが強化繊維を含む繊維強化フォームであることを特徴とする、請求項1に記載の扁平軽量部材。
- 前記スキン層から起毛した強化繊維が前記コア層に侵入していることを特徴とする、請求項1から3のいずれかに記載の扁平軽量部材。
- 前記端部補強層から起毛した強化繊維が前記コア層に侵入していることを特徴とする、請求項1から4のいずれかに記載の扁平軽量部材。
- 前記スキン層と前記端部補強層で囲まれた空間が閉空間であることを特徴とする、請求項1から5のいずれかに記載の扁平軽量部材。
- 前記端部補強層において、前記繊維強化樹脂シートが巻物構造または折畳構造を有することを特徴とする、請求項1から6のいずれかに記載の扁平軽量部材。
- 上型と下型からなる両面型を用いた扁平軽量部材の製造方法であって、
一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグを用いて、一方のスキン層と他方のスキン層とを準備するとともに、繊維強化樹脂シートを用いて端部補強層を準備する準備工程と、
前記一方のスキン層を成形温度に加熱した前記下型に配置し、前記端部補強層を前記一方のスキン層の周縁部の少なくとも一部に載置する第1配置工程と、
熱膨張性粒子と第2のマトリックス樹脂との混合物を前記一方のスキン層上に載置する投入工程と、
前記他方のスキン層を前記一方のスキン層の上面にさらに配置して前記端部補強層を前記他方のスキン層の周縁部の少なくとも一部に接触させる第2配置工程と、
成形温度に加熱した前記上型を閉じる型閉じ工程と、を有し、
さらに、前記熱膨張性粒子を体積膨張させてコア層とする工程を有することを特徴とする、扁平軽量部材の製造方法。 - 上型と下型からなる両面型を用いた扁平軽量部材の製造方法であって、
繊維強化樹脂シートからなる端部補強層を、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグからなる一方のスキン層の周縁部の少なくとも一部に接着し、端部補強層付きスキン層を準備するとともに、前記プリプレグからなる他方のスキン層を準備する準備工程と、
前記端部補強層付きスキン層を成形温度に加熱した前記下型に配置する第1配置工程と、
熱膨張性粒子と第2のマトリックス樹脂との混合物を前記一方のスキン層上に載置する投入工程と、
前記他方のスキン層を前記端部補強層付きスキン層の上面にさらに配置して前記端部補強層を前記他方のスキン層の周縁部の少なくとも一部に接触させる第2配置工程と、
成形温度に加熱した前記上型を閉じる型閉じ工程と、を有し、
さらに、前記熱膨張性粒子を体積膨張させてコア層とする工程を有することを特徴とする、扁平軽量部材の製造方法。 - 前記強化繊維樹脂シートが、一方向に引き揃えられた強化繊維と第1のマトリックス樹脂とからなるプリプレグであることを特徴とする、請求項8または9に記載の扁平軽量部材の製造方法。
- 前記強化繊維樹脂シートが、強化繊維を含む繊維強化フォームであることを特徴とする、請求項8または9に記載の扁平軽量部材の製造方法。
- 前記プリプレグとして、切込プリプレグを用いることを特徴とする、請求項8から11のいずれかに記載の扁平軽量部材の製造方法。
- 少なくとも前記一方のスキン層の、扁平軽量部材における内表面に相当する部位を、前記型閉じ工程の完了までに起毛させることを特徴とする、請求項8から12のいずれかに記載の扁平軽量部材の製造方法。
- 前記端部補強層の、扁平軽量部材における内表面に相当する部位を、前記型閉じ工程の完了までに起毛させることを特徴とする、請求項8から13のいずれかに記載の扁平軽量部材の製造方法。
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