CN113547800B - Carbon fiber-reinforced plastic sheet, processed product, and method for producing carbon fiber-reinforced plastic sheet - Google Patents

Carbon fiber-reinforced plastic sheet, processed product, and method for producing carbon fiber-reinforced plastic sheet Download PDF

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Publication number
CN113547800B
CN113547800B CN202110418120.3A CN202110418120A CN113547800B CN 113547800 B CN113547800 B CN 113547800B CN 202110418120 A CN202110418120 A CN 202110418120A CN 113547800 B CN113547800 B CN 113547800B
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carbon fiber
reinforced plastic
nonwoven fabric
plastic layer
orientation direction
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CN113547800A (en
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杉浦亮
保科有佑
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Futaba Corp
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Futaba Corp
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    • 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
    • B32B5/022—Non-woven fabric
    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating
    • 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
    • B32B5/06—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 a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • 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
    • B32B2262/106—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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The invention provides a carbon fiber reinforced plastic plate, a processed product and a manufacturing method of the carbon fiber reinforced plastic plate, wherein the carbon fiber reinforced plastic plate has isotropic strength without extreme deviation. The carbon fiber reinforced plastic sheet comprises: a first carbon fiber-reinforced plastic layer having a carbon fiber nonwoven fabric and a base material, the carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction; and a second carbon fiber-reinforced plastic layer having a carbon fiber nonwoven fabric and a base material, the carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction orthogonal to the orientation direction of the carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, at least each of the first carbon fiber-reinforced plastic layer and the second carbon fiber-reinforced plastic layer being laminated in the same number.

Description

Carbon fiber-reinforced plastic sheet, processed product, and method for producing carbon fiber-reinforced plastic sheet
Technical Field
The present invention relates to a carbon fiber-reinforced plastic sheet, a processed product, and a method for producing a carbon fiber-reinforced plastic sheet.
Background
Carbon fiber reinforced plastics (hereinafter sometimes referred to as "CFRP") are lightweight and have high strength, and are widely used in fields of construction such as reinforcement of buildings, in addition to sports applications such as fishing poles and shafts of golf clubs, industrial applications such as automobiles and airplanes, and the like.
For example, patent document 1 discloses a sewn substrate in which a plurality of sheets each including a plurality of carbon fiber filaments in a tow-like shape are arranged in parallel with each other, and the sheets are integrated by stitches in a state where the sheets are stacked at different angles with respect to the direction in which the carbon fiber filaments of the respective sheets are arranged.
Patent document 2 discloses a reinforcing fiber oriented sheet for composite material, which is produced by a method comprising a step of weighing 10g/m per unit area 2 The fiber web composed of a hot-melt adhesive is bonded to a monoaxially oriented reinforcing fiber sheet obtained by opening and expanding a reinforcing fiber bundle so that the width of each 1000 filaments becomes 1.3mm or more.
Prior art literature
Patent literature
Patent document 1: japanese patent No. 4534409
Patent document 2: japanese patent laid-open No. 2005-231151
Disclosure of Invention
Problems to be solved by the invention
As in patent documents 1 and 2, in the case of CFRP in which a carbon fiber woven fabric is impregnated with a base material, although the CFRP is excellent in strength in the same direction as the carbon fiber woven fabric, the CFRP is poor in strength in a direction different from the carbon fiber woven fabric. Therefore, CFRP, which is a woven fabric using carbon fibers, has anisotropic strength, and is not suitable for applications in which isotropic processed products are required to have no extreme variation in strength, such as rolls and grinding wheels.
Accordingly, an object of the present invention is to provide a carbon fiber reinforced plastic sheet, a processed product, and a method for producing a carbon fiber reinforced plastic sheet, which can satisfy the strength isotropy without extreme deviation.
In order to solve the above problems, a carbon fiber reinforced plastic sheet according to the present invention comprises: a first carbon fiber reinforced plastic layer having a first carbon fiber nonwoven fabric and a base material, wherein the first carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm and has an orientation direction; and a second carbon fiber-reinforced plastic layer having a second carbon fiber nonwoven fabric and a base material, the second carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction orthogonal to the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, at least each of the first carbon fiber-reinforced plastic layer and the second carbon fiber-reinforced plastic layer being laminated in the same number.
The present invention may be provided with: a third carbon fiber-reinforced plastic layer having a third carbon fiber nonwoven fabric and a base material, the third carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction intersecting with the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees; and a fourth carbon fiber-reinforced plastic layer having a fourth carbon fiber nonwoven fabric and a base material, the fourth carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction orthogonal to an orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber-reinforced plastic layer and intersecting an orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and an orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees, the first carbon fiber-reinforced plastic layer, the second carbon fiber-reinforced plastic layer, the third carbon fiber-reinforced plastic layer, and the fourth carbon fiber-reinforced plastic layer being laminated in at least the same number per layer.
The strength ratio of the first bending strength, the second bending strength, and the third bending strength may be 1:0.8 to 1.2:0.8 to 1.2, the first bending strength being bending strength in a direction parallel to the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer, the second bending strength being bending strength in a direction parallel to the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer, and the third bending strength being bending strength in a direction parallel to a crossing direction crossing the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees.
The ratio of the first flexural modulus to the second flexural modulus to the third flexural modulus may be 1:0.8 to 1.2:0.8 to 1.2, the first flexural modulus being a flexural modulus in a direction parallel to the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer, the second flexural modulus being a flexural modulus in a direction parallel to the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer, and the third flexural modulus being a flexural modulus in a direction parallel to a crossing direction crossing the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees.
The base material may be a thermosetting resin.
The fiber volume content of the carbon fiber nonwoven fabric may be 20 to 40% by volume relative to the carbon fiber reinforced plastic sheet.
The surface of the carbon fiber reinforced plastic plate may have a flatness of 0.005 to 0.05mm per 50 mm.
In order to solve the above problems, the processed product of the present invention is a processed product obtained by grinding the carbon fiber reinforced plastic sheet of the present invention.
The processed product may be a roll.
The processed product may be a grinding wheel.
In order to solve the above-described problems, a method for producing a carbon fiber-reinforced plastic sheet according to the present invention is a method for producing the above-described carbon fiber-reinforced plastic sheet, the method including a curing step of curing a laminate in which a base material is impregnated, the laminate being a laminate in which at least the first carbon fiber-reinforced plastic layer and the second carbon fiber-reinforced plastic layer are laminated in the same number.
The laminate may be a laminate in which at least each of the first carbon fiber-reinforced plastic layer, the second carbon fiber-reinforced plastic layer, the third carbon fiber-reinforced plastic layer, and the fourth carbon fiber-reinforced plastic layer is laminated in the same number.
The manufacturing method may include a milling step of milling the surface of the laminate after the curing step.
Effects of the invention
The present invention can provide a carbon fiber-reinforced plastic sheet, a processed product, and a method for producing a carbon fiber-reinforced plastic sheet, which can satisfy the strength isotropy to the extent that extreme deviations do not occur.
Drawings
Fig. 1 is a schematic perspective view of a carbon fiber nonwoven fabric illustrating the orientation direction of carbon fibers.
Fig. 2A and 2B are schematic perspective views of a carbon fiber reinforced plastic sheet 200 according to an embodiment of the present invention.
Fig. 3A and 3B are schematic perspective views of a carbon fiber reinforced plastic sheet 300 according to an embodiment of the present invention, which is different from fig. 2A and 2B.
Fig. 4A and 4B are schematic perspective views of the carbon fiber reinforced plastic plates 200 and 300.
Fig. 5A and 5B are perspective views of the roller 400 and the grinding wheel 500.
Fig. 6 is a graph showing the evaluation results of the bending strength of the carbon fiber reinforced plastic sheet in the examples.
Fig. 7 is a graph showing the results of evaluation of the elastic modulus of a carbon fiber reinforced plastic plate in examples.
Description of the reference numerals
100: a carbon fiber nonwoven fabric sheet; 101: a first carbon fiber nonwoven sheet; 102: a second carbon fiber nonwoven sheet; 103: a third carbon fiber nonwoven fabric sheet; 104: a fourth carbon fiber nonwoven fabric sheet; 111: a first carbon fiber reinforced plastic layer; 112: a second carbon fiber reinforced plastic layer; 113: a third carbon fiber reinforced plastic layer; 114: a fourth carbon fiber reinforced plastic layer; 200: a carbon fiber reinforced plastic plate; 300: a carbon fiber reinforced plastic plate; 400: a roller; 410: a use surface; 500: a grinding wheel; 510: a use surface; d1: orientation direction; d2: orientation direction; d3: and in the cross direction.
Detailed Description
Hereinafter, an embodiment of a carbon fiber-reinforced plastic sheet, a processed product, and a method for manufacturing a carbon fiber-reinforced plastic sheet according to the present invention will be described with reference to the accompanying drawings. The present invention is not limited to the following examples.
[ carbon fiber-reinforced Plastic Board ]
The carbon fiber reinforced plastic sheet of the present invention comprises a first carbon fiber reinforced plastic layer and a second carbon fiber reinforced plastic layer. Is a flexible, hard and rigid plate without CFRP sheet, prepreg or film.
First carbon fiber reinforced plastic layer
The first carbon fiber reinforced plastic layer is a layer having a first carbon fiber nonwoven fabric and a base material. The composite material layer is formed by combining non-woven fabrics serving as carbon fibers and a base material.
(first carbon fiber nonwoven fabric)
The carbon fiber nonwoven fabric usable in the present invention is a sheet-like fabric in which carbon fibers are three-dimensionally entangled with each other without knitting them. Carbon fibers have the advantage of being light and strong, for example, having a specific gravity of 1/4 times, a specific strength of 10 times, and a specific elastic modulus of 7 times as compared to iron. Further, the alloy is excellent in abrasion resistance, heat stretchability, acid resistance and electrical conductivity. For example, the carbon fiber can be produced by carbonizing an acrylic fiber or pitch as a raw material at a high temperature, and the carbon fiber may be a fiber composed of carbon in an amount of 90% or more by mass, which is obtained by heating and carbonizing a precursor of an organic fiber.
As the carbon fibers, PAN (Polyacrylonitrile) based carbon fibers, which are carbon fibers using acrylic fibers, and PITCH (PITCH) based carbon fibers, which are carbon fibers using PITCH, are classified. Further, in the case of pitch-based carbon fibers, a general-purpose carbon fiber is produced from isotropic pitch-based carbon fibers, and a high-strength and high-elastic modulus carbon fiber is produced from mesophase pitch-based carbon fibers. In the present invention, any PAN-based carbon fiber and pitch-based carbon fiber may be used. For example, pitch-based carbon fibers excellent in rigidity can be used to obtain CFRP having rigidity, and PAN-based carbon fibers excellent in strength can be used to obtain CFRP having strength.
As such a carbon fiber nonwoven fabric, for example, a PAN-based carbon fiber nonwoven fabric having a mass of 300 to 1500g/m can be used 2 Carbon fiber non-woven fabric with the thickness of 3-15 mm. In addition, a mixed fiber obtained by compounding rayon fiber, acrylic fiber, plastic resin fiber, and other various fibers with carbon fiber at a predetermined ratio may be used.
As the carbon fiber nonwoven fabric, it is advantageous that the cost of the carbon fiber nonwoven fabric for recycling the end material of the aircraft is lower than the case where the intermediate base material of the continuous fibers is the carbon fiber nonwoven fabric, because the end material of the aircraft can be recycled. Further, the carbon fiber nonwoven fabric is excellent in processability by suppressing fuzzing at the time of processing such as milling, and the processed product is smooth in surface state and excellent in finish property, as compared with the carbon fiber woven fabric.
(fiber length of carbon fiber)
The carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70 mm. The fiber length is 10 to 70mm, whereby carbon fibers can be three-dimensionally interlaced with each other by a needling method, and orientation can be imparted to the carbon fibers. When the fiber length is less than 10mm, it is difficult to three-dimensionally interweave carbon fibers, and thus a nonwoven fabric may not be formed. In addition, carbon fibers having a fiber length of more than 70mm have a problem that it is difficult to impart orientation to the carbon fibers due to the excessively long fiber length.
(orientation direction of fibers of carbon fiber nonwoven Fabric)
The direction of orientation of the fibers of the carbon fiber nonwoven fabric will be described with reference to fig. 1. Fig. 1 is a schematic perspective view of a carbon fiber nonwoven fabric illustrating the orientation direction of carbon fibers. The carbon fiber nonwoven fabric sheet 100 is a sheet formed by a needle punching method, and carbon fibers are oriented in the orientation direction indicated by the arrow. In the needling method, this orientation is achieved, for example, by puncturing the needle with projections known as barbs 10 times/cm 2 The traveling directions (i.e., machine directions) of the carbon fibers are orthogonal when the fibers are mechanically entangled with each other and processed into a nonwoven fabric.
However, unlike woven fabrics, in the case of nonwoven fabrics, carbon fibers are not all oriented in the same direction, but there are also carbon fibers oriented in directions different from the orientation direction, as shown by the broken lines. In the present invention, the direction in which the orientation ratio is highest is defined as the orientation direction. The mechanical properties in the direction in which the orientation ratio is highest become highest.
(parent material)
In the carbon fiber reinforced plastic sheet of the present invention, the base material is a material filling gaps between carbon fibers, and synthetic resin or natural resin can be used. From the viewpoint of securing strength as a CFRP plate, a thermosetting resin such as an epoxy resin or a urethane resin may be used as a base material. In addition, polybutylene succinate (PBS) and polyphenylene sulfide (PPS) may be used in terms of compatibility with carbon fibers.
In particular, when an epoxy resin is used as a base material, a copolymer of bisphenol a, bisphenol F and epichlorohydrin may be used as a main agent, and various kinds of acid anhydrides such as polyamine and phthalic anhydride may be used as a curing agent. In order to prevent the CFRP sheet from containing a solvent and to prevent the sheet from becoming thinner, a solvent-free resin is preferably used, and from the viewpoint of ease of compounding with carbon fibers, a resin that is liquid at ordinary temperature is preferably used as compared with a resin that is solid at ordinary temperature.
As the epoxy resin, specifically, a liquid solvent-free bisphenol a having an epoxy equivalent of 150 to 300 can be used as a main agent, and a diamino compound compatible and reactive-curable therewith can be used as a curing agent. For example, the CFRP plate can be produced by mixing the main agent with the curing agent and then compounding the mixture with carbon fibers before the pot life.
Second carbon fiber reinforced plastic layer
The second carbon fiber-reinforced plastic layer is a layer having a second carbon fiber nonwoven fabric and a base material, wherein the second carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm and has an orientation direction orthogonal to the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer. The details of the base material are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof will be omitted here.
(second carbon fiber nonwoven fabric)
The details of the carbon fiber nonwoven fabric that can be used for the second carbon fiber nonwoven fabric are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof is omitted here.
(orientation direction of second carbon fiber nonwoven Fabric)
The second carbon fiber nonwoven fabric is different from the first carbon fiber nonwoven fabric in that the orientation direction of the second carbon fiber nonwoven fabric is orthogonal to the orientation direction of the first carbon fiber nonwoven fabric. Accordingly, a nonwoven fabric in which the orientation direction of the same nonwoven fabric as that of the first carbon fiber nonwoven fabric is changed may be used as the second carbon fiber nonwoven fabric, or a nonwoven fabric different from the first carbon fiber nonwoven fabric may be used. However, in consideration of isotropy of strength of the carbon fiber reinforced plastic sheet, it is preferable to use a nonwoven fabric in which the orientation direction of the same nonwoven fabric as that of the first carbon fiber nonwoven fabric is changed as the second carbon fiber nonwoven fabric. The details of the orientation direction are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof is omitted here.
A specific example of the carbon fiber reinforced plastic sheet of the present invention will be described with reference to fig. 2A and 2B. Fig. 2A and 2B are schematic perspective views of a carbon fiber reinforced plastic sheet according to an embodiment of the present invention. Fig. 2A is a diagram of the four carbon fiber nonwoven fabric sheets 100 stacked in this order. When the left-right direction (the lateral direction in fig. 2A) in the sheet plane is the x direction, if the sheet of carbon fiber nonwoven fabric in which the direction d1 that is 90 degrees with respect to the x direction is the carbon fiber orientation direction is the first carbon fiber nonwoven fabric sheet 101, the sheet of carbon fiber nonwoven fabric in which the direction d2 that is 0 degrees with respect to the x direction, that is, the direction parallel to the x direction is the carbon fiber orientation direction is the second carbon fiber nonwoven fabric sheet 102.
Fig. 2B shows the four carbon fiber nonwoven fabric sheets 100 of fig. 2A, in which a first carbon fiber nonwoven fabric sheet 101 and a second carbon fiber nonwoven fabric sheet 102 are alternately laminated for every two sheets and are reinforced by a base material to form a carbon fiber reinforced plastic sheet 200. In the carbon fiber reinforced plastic sheet 200, the first carbon fiber nonwoven fabric sheet 101 and the second carbon fiber nonwoven fabric sheet 102 are reinforced by a base material to form a first carbon fiber reinforced plastic layer 111 and a second carbon fiber reinforced plastic layer 112.
In the carbon fiber-reinforced plastic sheet 200, at least the first carbon fiber-reinforced plastic layer 111 and the second carbon fiber-reinforced plastic layer 112 are laminated in the same number per layer. In this way, the carbon fiber-reinforced plastic layers having different orientation directions of the carbon fibers are laminated in the same number, and further, the carbon fibers oriented in the directions different from the orientation directions are present in the respective carbon fiber-reinforced plastic layers, whereby the carbon fiber-reinforced plastic sheet having isotropic strength without extreme deviation can be obtained.
Third carbon fiber reinforced plastic layer
The third carbon fiber-reinforced plastic layer is a layer having a third carbon fiber nonwoven fabric and a base material, wherein the third carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm, and has an orientation direction intersecting the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees. The details of the base material are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof will be omitted here.
(third carbon fiber nonwoven fabric)
The details of the carbon fiber nonwoven fabric that can be used for the third carbon fiber nonwoven fabric are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof is omitted here.
(orientation direction of third carbon fiber nonwoven Fabric)
The third carbon fiber nonwoven fabric is different from the first carbon fiber nonwoven fabric and the second carbon fiber nonwoven fabric in that the orientation direction of the third carbon fiber nonwoven fabric crosses the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees. Accordingly, a nonwoven fabric obtained by changing the orientation direction of the same nonwoven fabrics as the first carbon fiber nonwoven fabric and the second carbon fiber nonwoven fabric may be used as the third carbon fiber nonwoven fabric, or a nonwoven fabric different from the first carbon fiber nonwoven fabric and the second carbon fiber nonwoven fabric may be used. However, considering isotropy in strength of the carbon fiber reinforced plastic sheet, it is preferable to use a nonwoven fabric obtained by changing the orientation direction of the same nonwoven fabrics as the first carbon fiber nonwoven fabric and the second carbon fiber nonwoven fabric as the third carbon fiber nonwoven fabric. The details of the orientation direction are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof is omitted here.
Fourth carbon fiber reinforced plastic layer
The fourth carbon fiber-reinforced plastic layer is a layer having a fourth carbon fiber nonwoven fabric and a base material, wherein the fourth carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm, and has an orientation direction orthogonal to the orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber-reinforced plastic layer and intersecting the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees. The details of the base material are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof will be omitted here.
(fourth carbon fiber nonwoven fabric)
The details of the carbon fiber nonwoven fabric that can be used for the fourth carbon fiber nonwoven fabric are the same as those described in the item of the first carbon fiber reinforced plastic layer, and therefore, the description thereof is omitted here.
(orientation direction of fourth carbon fiber nonwoven fabric)
The fourth carbon fiber nonwoven fabric is different from the first carbon fiber nonwoven fabric, the second carbon fiber nonwoven fabric, and the third carbon fiber nonwoven fabric in that the orientation direction of the fourth carbon fiber nonwoven fabric is orthogonal to the orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber reinforced plastic layer, and intersects the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees. Accordingly, a nonwoven fabric obtained by changing the orientation direction of the same nonwoven fabrics as the first carbon fiber nonwoven fabric, the second carbon fiber nonwoven fabric, and the third carbon fiber nonwoven fabric may be used as the fourth carbon fiber nonwoven fabric, or a nonwoven fabric different from the first carbon fiber nonwoven fabric, the second carbon fiber nonwoven fabric, or the third carbon fiber nonwoven fabric may be used. However, in consideration of isotropy in strength of the carbon fiber reinforced plastic sheet, it is preferable to use a nonwoven fabric obtained by changing the orientation direction of the same nonwoven fabrics as the first carbon fiber nonwoven fabric, the second carbon fiber nonwoven fabric, and the third carbon fiber nonwoven fabric as the fourth carbon fiber nonwoven fabric. The details of the orientation direction are the same as those described in the item < first carbon fiber reinforced plastic layer >, and therefore, description thereof is omitted here
A specific example of the carbon fiber reinforced plastic sheet according to the present invention, which is different from fig. 2A and 2B, will be described with reference to fig. 3A and 3B. As a mode different from fig. 2A and 2B, a schematic perspective view of a carbon fiber reinforced plastic sheet according to an embodiment of the present invention is shown. Fig. 3A is a diagram of the stacking of eight carbon fiber nonwoven fabric sheets 100 in this order. When the left-right direction (the lateral direction in fig. 3A) in the sheet plane is the x direction, if the sheet of carbon fiber nonwoven fabric in which the direction d1 that is 90 degrees with respect to the x direction is the carbon fiber orientation direction is the first carbon fiber nonwoven fabric sheet 101, the sheet of carbon fiber nonwoven fabric in which the direction d2 that is 0 degrees with respect to the x direction, that is, the direction parallel to the x direction is the carbon fiber orientation direction is the second carbon fiber nonwoven fabric sheet 102.
The sheet of carbon fiber nonwoven fabric having the direction d3 at 45 degrees with respect to the x-direction as the orientation direction of the carbon fibers becomes the third carbon fiber nonwoven fabric sheet 103. The orientation direction of the carbon fibers of the third carbon fiber nonwoven fabric sheet 103 intersects the orientation direction of the carbon fibers of the first carbon fiber nonwoven fabric sheet 101 and the orientation direction of the carbon fibers of the second carbon fiber nonwoven fabric sheet 102 at an angle of 45 degrees.
Further, the sheet of carbon fiber nonwoven fabric having a direction d4 of 135 degrees with respect to the x-direction as the orientation direction of the carbon fibers becomes the fourth carbon fiber nonwoven fabric sheet 104. The orientation direction of the carbon fibers of the fourth carbon fiber nonwoven fabric sheet 104 intersects the orientation direction of the carbon fibers of the first carbon fiber nonwoven fabric sheet 101 and the orientation direction of the carbon fibers of the second carbon fiber nonwoven fabric sheet 102 at an angle of 45 degrees, and is orthogonal to the orientation direction of the carbon fibers of the third carbon fiber nonwoven fabric sheet 103.
In fig. 3B, the eight carbon fiber nonwoven fabric sheets 100 in fig. 3A are sheets obtained by stacking two first carbon fiber nonwoven fabric sheets 101, four carbon fiber nonwoven fabric sheets 104, third carbon fiber nonwoven fabric sheets 103, and second carbon fiber nonwoven fabric sheets 102 in this order, and reinforcing the two sheets by a base material, thereby forming a carbon fiber reinforced plastic sheet 300. In the carbon fiber-reinforced plastic sheet 300, the first carbon fiber nonwoven fabric sheet 101, the second carbon fiber nonwoven fabric sheet 102, the third carbon fiber nonwoven fabric sheet 103, and the fourth carbon fiber nonwoven fabric sheet 104 are reinforced by a base material to form a first carbon fiber-reinforced plastic layer 111, a second carbon fiber-reinforced plastic layer 112, a third carbon fiber-reinforced plastic layer 113, and a fourth carbon fiber-reinforced plastic layer 114.
In the carbon fiber-reinforced plastic sheet 300, at least each of the first carbon fiber-reinforced plastic layer 111, the second carbon fiber-reinforced plastic layer 112, the third carbon fiber-reinforced plastic layer 113, and the fourth carbon fiber-reinforced plastic layer 114 is laminated in the same number. In this way, since the carbon fiber-reinforced plastic layers having different carbon fiber orientation directions are laminated in the same number, and the carbon fibers oriented in the directions different from the orientation directions are present in the respective carbon fiber-reinforced plastic layers, the carbon fiber-reinforced plastic sheet having isotropic strength can be obtained without extreme deviation. Further, by providing the third carbon fiber-reinforced plastic layer 113 and the fourth carbon fiber-reinforced plastic layer 114, the carbon fiber-reinforced plastic sheet 300 can satisfy the strength more isotropically than the carbon fiber-reinforced plastic sheet 200.
(other structures)
The carbon fiber-reinforced plastic sheet of the present invention may have other structures in addition to the first to fourth carbon fiber-reinforced plastic layers. For example, when the first to fourth carbon fiber-reinforced plastic layers are bonded and laminated, a resin-based adhesive layer having good compatibility with the base material may be provided between the layers. In order to avoid damage to the surfaces of the first to fourth carbon fiber-reinforced plastic layers and contamination of the surfaces, a protective layer, a protective film, or the like may be provided to protect the surfaces of the carbon fiber-reinforced plastic plates immediately before the carbon fiber-reinforced plastic plates are used.
Fig. 4A and 4B are schematic perspective views of the carbon fiber reinforced plastic plates 200 and 300. On the same plane of each of the carbon fiber-reinforced plastic sheets 200 and 300, an arrow indicating the direction of orientation D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, an arrow indicating the direction of orientation D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer, and an arrow indicating the direction of intersection D3 intersecting the direction of orientation D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the direction of orientation D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees are shown. In the carbon fiber reinforced plastic sheet 300, the intersecting direction D3 is the orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber reinforced plastic layer, and is the orientation direction of the fourth carbon fiber nonwoven fabric of the fourth carbon fiber reinforced plastic layer.
In the carbon fiber-reinforced plastic sheets 200 and 300, the strength ratio of the bending strength (first bending strength) in the direction parallel to the orientation direction D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, the bending strength (second bending strength) in the direction parallel to the orientation direction D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer, and the bending strength (third bending strength) in the direction parallel to the intersecting direction D3 in which the orientation direction D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer intersect at an angle of 45 degrees is preferably the following ratio.
First bending strength, second bending strength, third bending strength=1:0.8-1.2:0.8-1.2
The carbon fiber reinforced plastic sheet of the present invention can satisfy more isotropic strength by satisfying the strength ratio as described above. If the strength ratio does not satisfy the above ratio, the strength may be anisotropic, and thus the strength in a predetermined direction may be extremely reduced.
The carbon fiber reinforced plastic sheet 300 also has a bending strength of 80% to 120% of the direction D1 in the intersecting direction D4 intersecting the direction D1 and the direction D3 at an angle of 22.5 degrees and in the intersecting direction D5 intersecting the direction D2 and the direction D3 at an angle of 22.5 degrees. Accordingly, the carbon fiber reinforced plastic sheet 300 can satisfy more isotropic strength than the carbon fiber reinforced plastic sheet 200.
In the carbon fiber-reinforced plastic sheets 200 and 300, the ratio of the flexural modulus of elasticity (first flexural modulus) in the direction parallel to the orientation direction D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, the flexural modulus of elasticity (second flexural modulus of elasticity) in the direction parallel to the orientation direction D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer, and the flexural modulus of elasticity (third flexural modulus of elasticity) in the direction parallel to the intersecting direction intersecting the orientation direction D1 of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction D2 of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees is preferably the following ratio.
The first bending elastic modulus, the second bending elastic modulus and the third bending elastic modulus=1:0.8-1.2:0.8-1.2.
The carbon fiber-reinforced plastic sheet of the present invention can satisfy more isotropic elasticity by satisfying the above ratio of the elastic modulus. If the ratio of the elastic modulus does not satisfy the above ratio, the elasticity may have anisotropy, and thus the elasticity in a predetermined direction may be extremely reduced.
The carbon fiber reinforced plastic sheet 300 also has an elastic modulus of 80% to 120% in the direction D1 with respect to the intersecting direction D4 intersecting the direction D1 and the direction D3 at an angle of 22.5 degrees and the intersecting direction D5 intersecting the direction D2 and the direction D3 at an angle of 22.5 degrees. Accordingly, the carbon fiber reinforced plastic sheet 300 can satisfy more isotropic elasticity than the carbon fiber reinforced plastic sheet 200.
As the carbon fiber reinforced plastic sheet of the present invention, a sheet having a thickness of usually 5 to 100mm, particularly a sheet having a thickness of 8 to 40mm is usually used.
In the present invention, the fiber volume fraction (Vf) of the carbon fiber nonwoven fabric relative to the carbon fiber-reinforced plastic sheet of the present invention is preferably 20 to 40% by volume in each of the first to fourth carbon fiber-reinforced plastic layers. If Vf is high, there is an advantage that mechanical properties and physical properties are excellent, but there is a risk that it is difficult to form the first to fourth carbon fiber reinforced plastic layers because the amount of the base material becomes small. In addition, if Vf is high, there is a risk of deterioration in toughness, workability, and surface smoothness. On the other hand, if Vf is low, the characteristics of the base material are preferentially exhibited, and there is a risk that the reinforcing effect by the carbon fiber is impaired. In view of these points, in the case of the first to fourth carbon fiber-reinforced plastic layers, by setting Vf to 20 to 40% by volume in any layer, the workability and the surface smoothness can be satisfied.
In the present invention, the surface of the carbon fiber reinforced plastic sheet of the present invention may have a flatness of 0.005 to 0.05mm per 50 mm. For example, by milling the surface of the carbon fiber reinforced plastic sheet, such a planar surface can be obtained. In the case where smoothness of the surface of the carbon fiber reinforced plastic sheet is required, the surface flatness of the carbon fiber reinforced plastic sheet of the present invention is more preferably 0.005 to 0.05mm per 100 mm. In addition, in the case where smoothness of the surface of the carbon fiber reinforced plastic sheet is more strictly required, the flatness of the surface of the carbon fiber reinforced plastic sheet of the present invention is more preferably 0.005 to 0.05mm per 500 mm.
[ processed product ]
The processed product of the present invention is a processed product obtained by grinding the carbon fiber reinforced plastic sheet of the present invention. Such a processed product is not particularly limited. For example, a roll or a grinding wheel used by rotating the workpiece is exemplified as a processed product requiring a strength having a certain degree of isotropy. Fig. 5A and 5B show perspective views of the roller 400 and the grinding wheel 500, as an example.
During use by rotating the roller or the grinding wheel, the load is applied uniformly to the use surfaces 410 and 510 and the vicinity of the roller or the grinding wheel, and therefore, the strength of the use surfaces 410 and 510 is preferably uniform. The carbon fiber reinforced plastic sheet of the present invention can satisfy isotropic strength to such an extent that the strength required for such a use surface can be satisfied.
[ method for producing carbon fiber-reinforced Plastic Board ]
Next, a method for producing the carbon fiber reinforced plastic sheet of the present invention will be described.
Curing process
The curing step is a step of curing the laminate impregnated with the base material. For example, if the base material is a thermosetting resin, it can be cured by heating. In the case of the thermoplastic resin, the resin may be impregnated into the carbon fiber nonwoven fabric in a state of being heated and melted, and then cooled to room temperature to be solidified.
(laminate)
The laminate may be a laminate in which at least the first carbon fiber-reinforced plastic layer 101 and the second carbon fiber-reinforced plastic layer 102 are laminated in the same number per layer. By curing such a laminate, the carbon fiber reinforced plastic panel 200 and the carbon fiber reinforced plastic panel 300 can be manufactured.
The laminate may be a laminate in which at least the first carbon fiber-reinforced plastic layer 101, the second carbon fiber-reinforced plastic layer 102, the third carbon fiber-reinforced plastic layer 103, and the fourth carbon fiber-reinforced plastic layer 104 are laminated in the same number. By curing such a laminate, the carbon fiber reinforced plastic panel 300 can be manufactured.
As a manufacturing procedure of the carbon fiber-reinforced plastic sheet of the present invention, the first carbon fiber-reinforced plastic layer 101, the second carbon fiber-reinforced plastic layer 102, and the like may be laminated as a laminate before the curing step, and the laminate may be impregnated with a base material, and then the curing step may be performed. Further, the carbon fiber-reinforced plastic sheet may be produced by immersing the base material in the first carbon fiber-reinforced plastic layer 101, the second carbon fiber-reinforced plastic layer 102, and the like, respectively, and then laminating them to form a laminate, and then performing the curing step.
In addition, a plurality of carbon fiber reinforced plastic plates 200 may be bonded by an adhesive to form a carbon fiber reinforced plastic plate 200 having an increased thickness. In the same manner as in the case of the carbon fiber reinforced plastic sheet 300, a plurality of carbon fiber reinforced plastic sheets 300 may be bonded by an adhesive to form the carbon fiber reinforced plastic sheet 300 having an increased thickness. In addition, when there is a risk of lowering the strength of the carbon fiber reinforced plastic sheet due to the presence of the adhesive layer, for example, the carbon fiber reinforced plastic sheet without the adhesive layer can be produced by impregnating the base material into the laminate by the Va RTM method, and then curing at room temperature and heating.
Milling process
In the present invention, after the curing step, a step of milling the surface of the laminate may be provided, and in order to improve the surface smoothness of the CFRP plate, for example, milling may be performed when the flatness of the surface is set to 0.005 to 0.05mm per 50 mm.
(other procedure)
The method for producing a carbon fiber-reinforced plastic sheet of the present invention may have other configurations in addition to the curing step and the milling step. For example, a lamination step of laminating the first to fourth carbon fiber nonwoven fabrics by adjusting the orientation direction of the fibers to obtain a laminate, and an impregnation step of impregnating the laminate with the base material may be mentioned.
Examples (example)
Hereinafter, the present invention will be described in further detail by way of examples, but the present invention is not limited to the examples. In the following examples, carbon fiber reinforced plastic sheets were produced, and the produced carbon fiber reinforced plastic sheets were subjected to milling, bending strength, and elastic modulus evaluation.
[ production of carbon fiber-reinforced Plastic Board ]
Example 1
Four nonwoven carbon fiber sheets (CFZ-1000 SD manufactured by Japanese Polymer Co., ltd.) produced by needle punching were placed in a mold (inner dimension: 15X 1 cm). As shown in fig. 2A, the first carbon fiber nonwoven fabric sheet 101 and the second carbon fiber nonwoven fabric sheet 102 are alternately stacked one on another so that the orientation directions of the carbon fibers are different by 90 degrees. The same carbon fiber nonwoven fabric sheet is used as the first carbon fiber nonwoven fabric sheet 101 and the second carbon fiber nonwoven fabric sheet 102. Then, after mixing an epoxy resin main agent (jER 806 manufactured by mitsubishi chemical Co., ltd.) and a curing agent (4, 4' -methylenebis (2-methylcyclohexylamine) manufactured by tokyo chemical Co., ltd.) at a mass ratio of 100:36, the mixed resin was pressurized and injected into a closed mold heated to 100℃at a pressure of 0.5 MPa. After the mixed resin was injected, the resin was cured by heating at 100℃for 20 minutes to obtain a carbon fiber reinforced plastic plate 200 having a thickness of 10mm and a Vf of 21 vol%. In addition, carbon fiber woven cloth is not used.
Example 2
Eight nonwoven carbon fiber sheets (CFZ-1000 SD manufactured by Japanese Polymer Co., ltd.) produced by needle punching were placed in a mold (inner dimension: 15X 1 cm). Here, as shown in fig. 3A, the first carbon fiber nonwoven fabric sheet 101, the fourth carbon fiber nonwoven fabric sheet 104, the third carbon fiber nonwoven fabric sheet 103, and the second carbon fiber nonwoven fabric sheet 102 are laminated in this order. The same carbon fiber nonwoven fabric sheets are used as the first carbon fiber nonwoven fabric sheet 101, the second carbon fiber nonwoven fabric sheet 102, the third carbon fiber nonwoven fabric sheet 103, and the fourth carbon fiber nonwoven fabric sheet 104. Then, after mixing an epoxy resin main agent (jER 806 manufactured by mitsubishi chemical Co., ltd.) and a curing agent (4, 4' -methylenebis (2-methylcyclohexylamine) manufactured by tokyo chemical Co., ltd.) at a mass ratio of 100:36, the mixed resin was pressurized and injected into a closed mold heated to 100℃at a pressure of 0.5 MPa. After the mixed resin was injected, the resin was cured by heating at 100℃for 20 minutes to obtain a carbon fiber reinforced plastic plate 300 having a thickness of 20mm and a Vf of 21 vol%. In addition, carbon fiber woven cloth is not used.
Comparative example 1
Carbon fibers each comprising 10 layers of carbon fiber woven cloth (BT 70-20 manufactured by Toli Co., ltd.) each having a length of 12cm and a width of 12cm were stacked on a metal plate, and the periphery of the carbon fibers was sealed with a film and a sealant to prevent leakage of the base material. Then, after mixing an epoxy resin main agent (jER 806 manufactured by mitsubishi chemical Co., ltd.) and a curing agent (1, 3-BAC manufactured by mitsubishi gas chemical Co., ltd.) at a mass ratio of 100:21, the mixed resin was injected into carbon fibers by the Va RTM method. After the injection, it was cured at room temperature, and further, heat-cured at 150℃for 60 minutes, to obtain a carbon fiber-reinforced plastic plate having a thickness of 2mm and a Vf of 57% by volume. In addition, carbon fiber nonwoven fabrics are not used.
Comparative example 2
Four nonwoven carbon fiber sheets (CFZ-1000 SD manufactured by Japanese Polymer Co., ltd.) produced by needle punching were placed in a mold (inner dimension: 15X 1 cm). Here, the carbon fiber nonwoven fabric sheets of each layer are stacked with the carbon fibers aligned in the same direction. Then, after mixing an epoxy resin main agent (jER 806 manufactured by mitsubishi chemical Co., ltd.) and a curing agent (4, 4' -methylenebis (2-methylcyclohexylamine) manufactured by tokyo chemical Co., ltd.) at a mass ratio of 100:36, the mixed resin was pressurized and injected into a closed mold heated to 100℃at a pressure of 0.5 MPa. After the mixed resin was injected, the resin was cured by heating at 100℃for 20 minutes to obtain a carbon fiber-reinforced plastic plate having a thickness of 10mm and a Vf of 21 vol%. In addition, carbon fiber woven cloth is not used.
[ evaluation of flatness after milling ]
Milling treatment
Using three carbon fiber reinforced plastic plates of example 1, example 2, comparative example 1 and comparative example 2, the surfaces were milled by grinding of 0.5mm under the following conditions.
(milling conditions)
The device comprises: screw-in type universal front milling machine (Mitsubishi comprehensive material manufacturing)
Cutter model: ASX44R10005D
Insert: SEGT13T3AGFN-JP HTi10
Rotational speed: s=615 min -1 (V＝193m/min)
Feed rate: f=369 mm/min
The carbon fiber-reinforced plastic sheets of example 1, example 2, comparative example 1 and comparative example 2 after milling were measured for the flatness of their surfaces (the amount of deviation from the geometrically correct plane of the planar body) using a three-dimensional precision measuring machine (model: UPMC 850, manufactured by ZEISS Co.). The average of the flatness of the three carbon fiber reinforced plastic plates of each example is shown in table 1.
TABLE 1
Figure GDA0003121528280000161
In the carbon fiber reinforced plastic sheets of example 1, example 2 and comparative example 2, the carbon fiber nonwoven fabric was used instead of the carbon fiber woven fabric, and the flatness after milling was not problematic, and the flatness was high.
On the other hand, the carbon fiber reinforced plastic sheet of comparative example 1 in which the carbon fiber nonwoven fabric was not used but the carbon fiber woven fabric was subjected to milling to form a fiber fluff, and the value of flatness was increased by the fluff, and the sheet was a sheet with low flatness.
[ evaluation of flexural Strength and elastic modulus ]
The carbon fiber-reinforced plastic sheet 200 of example 1 was subjected to the bending test in the D1, D2, and D3 directions shown in fig. 4A under the following conditions based on JIS K7074, and the bending strength and the elastic modulus in the D2 and D3 directions were compared with each other, assuming that the bending strength and the elastic modulus in the D1 direction were 100%. The results of the flexural strength are shown in fig. 6, and the results of the elastic modulus are shown in fig. 7. Similarly, the carbon fiber-reinforced plastic sheet of comparative example 1 was also compared with the flexural strength and the elastic modulus in the D1, D2, and D3 directions, and is shown in fig. 6 and 7.
Size of test piece: 100X 15mm, thickness of 2mm
Test speed: 5 mm/min
Distance between fulcrums L: l=40×h (80 mm)
Radius of ram R1: r1=5 mm
Radius R2 of support table: r2=2mm
Flexural modulus of elasticity: tangent line method
The carbon fiber-reinforced plastic sheet of example 1 has a bending strength ratio in the D1 to D3 directions of d1:d2:d3=100:101:98, and a bending elastic modulus ratio of d1:d2:d3=100:101:96, and thus it is found that the sheet satisfies strength and elasticity isotropy to such an extent that there is no extreme deviation. In the case of the carbon fiber reinforced plastic sheet, the sheet is useful for the use as a roller or a grinding wheel for rotating the sheet.
On the other hand, the carbon fiber-reinforced plastic sheet of comparative example 1 had a bending strength ratio in the D1 to D3 directions of d1:d2:d3=100:114:30, and a bending elastic modulus ratio of d1:d2:d3=100:88:30, and thus had a weak strength in the D3 direction and a weak elasticity. The carbon fiber woven fabric used in comparative example 1 was woven using warp yarns and weft yarns, and had a constant strength and elasticity by setting the D1 direction and the D2 direction to be parallel to either of the warp yarns and the weft yarns of the carbon fiber woven fabric. On the other hand, the D3 direction is a direction intersecting the warp and weft at an angle of 45 degrees, and the reinforcing effect by the carbon fiber is insufficient, and the strength and elasticity are inferior to those in the D1 direction and the D2 direction. From the results, it was found that the carbon fiber reinforced plastic sheet of comparative example 1 had weak strength and elasticity in the D3 direction and had anisotropy in strength and elasticity, and therefore was unsuitable for use as a roller or grinding wheel for rotating the sheet.
Summary
In this way, the carbon fiber-reinforced plastic sheet of the present invention can satisfy strength having isotropy to the extent that there is no extreme deviation, and can satisfy milling property and smoothness after milling. Therefore, the carbon fiber reinforced plastic sheet of the present invention is useful for applications such as rollers and grinding wheels used for rotating the sheet.

Claims (13)

1. The carbon fiber reinforced plastic sheet is characterized by comprising:
a first carbon fiber-reinforced plastic layer having a first carbon fiber nonwoven fabric and a base material, wherein the first carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm and has an orientation direction, and is a sheet-like fabric in which the carbon fibers are three-dimensionally interwoven by a needling method without braiding the carbon fibers; and
a second carbon fiber-reinforced plastic layer having a second carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction orthogonal to the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer, and a base material, the second carbon fiber nonwoven fabric being a sheet-like fabric in which the carbon fibers are three-dimensionally entangled with each other by a needle punching method without knitting the carbon fibers,
at least the first carbon fiber-reinforced plastic layer and the second carbon fiber-reinforced plastic layer are laminated in the same number per layer.
2. The carbon fiber reinforced plastic sheet according to claim 1, wherein the carbon fiber reinforced plastic sheet comprises:
a third carbon fiber-reinforced plastic layer having a third carbon fiber nonwoven fabric and a base material, wherein the third carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm and has an orientation direction intersecting with an orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and an orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees, and is a sheet-like fabric in which the carbon fibers are three-dimensionally interwoven by a needle punching method without knitting the carbon fibers; and
A fourth carbon fiber-reinforced plastic layer having a fourth carbon fiber nonwoven fabric and a base material, wherein the fourth carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm, has a sheet-like fabric which is orthogonal to the orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber-reinforced plastic layer and which is intersected with the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees, and is formed by three-dimensionally interweaving the carbon fibers by a needle punching method without knitting the carbon fibers,
the first carbon fiber-reinforced plastic layer, the second carbon fiber-reinforced plastic layer, the third carbon fiber-reinforced plastic layer, and the fourth carbon fiber-reinforced plastic layer are laminated in at least the same number per layer.
3. A carbon fiber reinforced plastic board according to claim 1 or 2, wherein,
the strength ratio of the first bending strength, the second bending strength and the third bending strength is 1:0.8-1.2:0.8-1.2,
the first bending strength is bending strength in a direction parallel to an orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer;
The second bending strength is bending strength in a direction parallel to an orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer; and
the third bending strength is a bending strength in a direction parallel to a crossing direction crossing an orientation direction of the first carbon fiber non-woven fabric of the first carbon fiber reinforced plastic layer and an orientation direction of the second carbon fiber non-woven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees.
4. A carbon fiber reinforced plastic board according to claim 1 or 2, wherein,
the ratio of the first bending elastic modulus, the second bending elastic modulus and the third bending elastic modulus is 1:0.8-1.2:0.8-1.2,
the first flexural modulus of elasticity is a flexural modulus of elasticity in a direction parallel to an orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber reinforced plastic layer;
the second flexural modulus of elasticity is a flexural modulus of elasticity in a direction parallel to an orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber reinforced plastic layer; and
the third flexural modulus is a flexural modulus in a direction parallel to a crossing direction crossing an orientation direction of the first carbon fiber non-woven fabric of the first carbon fiber reinforced plastic layer and an orientation direction of the second carbon fiber non-woven fabric of the second carbon fiber reinforced plastic layer at an angle of 45 degrees.
5. The carbon fiber reinforced plastic panel according to claim 1 or 2, wherein the base material is a thermosetting resin.
6. The carbon fiber-reinforced plastic sheet according to claim 1 or 2, wherein the fiber volume content of the carbon fiber nonwoven fabric with respect to the carbon fiber-reinforced plastic sheet is 20 to 40% by volume.
7. Carbon fiber reinforced plastic sheet according to claim 1 or 2, characterized in that the flatness of the surface of the carbon fiber reinforced plastic sheet is 0.005-0.05 mm per 50 mm.
8. A processed product, characterized in that the processed product is a processed product obtained by grinding the carbon fiber reinforced plastic sheet according to any one of claims 1 to 7.
9. The article of manufacture of claim 8, wherein the article of manufacture is a roll.
10. The work of claim 8 wherein the work is a grinding wheel.
11. A method for producing a carbon fiber-reinforced plastic sheet according to any one of claims 1 to 7, characterized in that the method comprises a curing step of curing the laminate impregnated with the base material,
The laminate is a laminate in which at least the first carbon fiber-reinforced plastic layer and the second carbon fiber-reinforced plastic layer are laminated in the same number.
12. The method for producing a carbon fiber-reinforced plastic sheet according to claim 11, wherein,
the laminate is a laminate in which at least each of the first carbon fiber-reinforced plastic layer, the second carbon fiber-reinforced plastic layer, the third carbon fiber-reinforced plastic layer, and the fourth carbon fiber-reinforced plastic layer is laminated in the same number,
the third carbon fiber-reinforced plastic layer is a layer having a third carbon fiber nonwoven fabric and a base material, the third carbon fiber nonwoven fabric containing carbon fibers having a fiber length of 10 to 70mm and having an orientation direction intersecting with the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees; and
the fourth carbon fiber-reinforced plastic layer is a layer having a fourth carbon fiber nonwoven fabric and a base material, wherein the fourth carbon fiber nonwoven fabric contains carbon fibers having a fiber length of 10 to 70mm, and has an orientation direction orthogonal to the orientation direction of the third carbon fiber nonwoven fabric of the third carbon fiber-reinforced plastic layer and intersecting the orientation direction of the first carbon fiber nonwoven fabric of the first carbon fiber-reinforced plastic layer and the orientation direction of the second carbon fiber nonwoven fabric of the second carbon fiber-reinforced plastic layer at an angle of 45 degrees.
13. The method of manufacturing a carbon fiber-reinforced plastic sheet according to claim 11 or 12, characterized in that the manufacturing method includes a milling process of milling the surface of the laminate after the curing process.
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